The announcement strengthens the long-standing relationship between the two companies and marks a significant step in CASI’s expansion into the European market.

The new agreement will see TM Robotics lead direct customer engagement across the UK and mainland Europe, providing in-region support and tailored automation solutions. Backed by over fifteen years of collaboration, the partnership is focused on bringing CASI’s warehouse automation systems to a wider customer base outside of North America.

“TM Robotics has the local market knowledge and technical expertise to help us better serve customers internationally,” explained Greg Judkins, chief executive officer at CASI. “While we continue to support our existing global installations remotely, this development allows us to offer face-to-face support to businesses we would otherwise struggle to reach.”

The move supports CASI’s strategic approach to international growth by leveraging TM Robotics’ well-established presence and industry network across Europe. The partnership will also increase accessibility to CASI’s complete range of turnkey automation systems – including conveyor technologies, box cutting equipment and intelligent sorting solutions – for customers across warehousing, distribution and logistics sectors.

TM Robotics is already widely recognised for its automation expertise through its exclusive distribution of Shibaura Machine’s SCARA industrial robots, as well as its injection moulding machines (IMMs) in the UK and Ireland. Its logistics range includes solutions such as the CASi-iBOD, which stands for intelligent Box Opening Device, designed to streamline box-opening processes in European warehousing.

The CASi-IBOD is an inline robotic system designed to automate box opening within existing conveyor setups. It uses real-time dimensional scanning and adjustable cutting paths to handle varying box sizes and product types without manual sorting. This approach improves consistency, reduces handling risks and supports higher throughput in warehouse and distribution environments.

“This expanded role with CASI reflects the strength of our existing relationship and shared focus on delivering effective automation solutions,” said Nigel Smith, CEO of TM Robotics. “By working closely with CASI’s team, we’re able to provide customers in the UK and Europe with local support and tailored services that meet the demands of modern warehousing.”

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The announcement strengthens the long-standing relationship between the two companies and marks a significant step in CASI’s expansion into the European market.

The new agreement will see TM Robotics lead direct customer engagement across the UK and mainland Europe, providing in-region support and tailored automation solutions. Backed by over fifteen years of collaboration, the partnership is focused on bringing CASI’s warehouse automation systems to a wider customer base outside of North America.

“TM Robotics has the local market knowledge and technical expertise to help us better serve customers internationally,” explained Greg Judkins, chief executive officer at CASI. “While we continue to support our existing global installations remotely, this development allows us to offer face-to-face support to businesses we would otherwise struggle to reach.”

The move supports CASI’s strategic approach to international growth by leveraging TM Robotics’ well-established presence and industry network across Europe. The partnership will also increase accessibility to CASI’s complete range of turnkey automation systems – including conveyor technologies, box cutting equipment and intelligent sorting solutions – for customers across warehousing, distribution and logistics sectors.

TM Robotics is already widely recognised for its automation expertise through its exclusive distribution of Shibaura Machine’s SCARA industrial robots, as well as its injection moulding machines (IMMs) in the UK and Ireland. Its logistics range includes solutions such as the CASi-iBOD, which stands for intelligent Box Opening Device, designed to streamline box-opening processes in European warehousing.

The CASi-IBOD is an inline robotic system designed to automate box opening within existing conveyor setups. It uses real-time dimensional scanning and adjustable cutting paths to handle varying box sizes and product types without manual sorting. This approach improves consistency, reduces handling risks and supports higher throughput in warehouse and distribution environments.

“This expanded role with CASI reflects the strength of our existing relationship and shared focus on delivering effective automation solutions,” said Nigel Smith, CEO of TM Robotics. “By working closely with CASI’s team, we’re able to provide customers in the UK and Europe with local support and tailored services that meet the demands of modern warehousing.”

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A standout feature of Shibaura Machine’s exhibit will be a fully automated production cell, where the TVM900 6-axis robot will seamlessly integrate with the advanced EC75SXIII injection moulding machine. This live demonstration will showcase real-time production of plastic business card cases.

The SXIII series is an all-electric line-up of injection moulding machines designed for high-speed, energy-efficient operation. With 16 different models tailored to varying tonnage requirements, the SXIII features the V70 controller for smooth integration, optimised cycle times and enhanced productivity.

The injection mould machine will collaborate with the TVM900 robot – one of Shibaura Machine’s comprehensive ranges of 6-axis robots. With a 900 mm reach and 20 kg payload capacity, robots in the TVM range offer rapid, smooth motion control and high repeatability.

Complementing this, the RoboPrint printing head will accurately transfer logos and designs onto the moulded plastic parts, demonstrating the potential of robotic integration for speed and efficiency.

“Robotic integration in injection moulding is transforming the industry,” explained Nigel Smith, managing director of TM Robotics, the premier Shibaura Machine robotics distributor in Europe. “By automating repetitive tasks, such as part handling, assembly and quality control, manufacturers can meet rising demand while maintaining consistent quality – all of which contribute to a faster return on investment.”

Dr. Georg Holzinger, executive vice president of Shibaura Machine Europe, added: “As a trusted Japanese manufacturer with over 75 years of experience, Shibaura Machine was one of the first to develop all-electric injection moulding machines in the 1990s. Today, its machines are engineered for unmatched precision, energy efficiency and reliability. This technology, working alongside our industrial robots, demonstrates our commitment to providing complete solutions for the plastics sector.”

Additionally, Shibaura Machine will showcase its TV1000 6-axis robot. With a 1,000 mm reach and 10 kg payload capacity, the TV1000 excels in material handling, assembly, machine tending and packaging applications.

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At the event, TM Robotics will be showcasing the THE400 and THE600 SCARA robot models in a live, high-speed part handling operation, demonstrating the precision and throughput capabilities of the series. These models are part of a growing portfolio of SCARA solutions designed for assembly, inspection and packaging tasks in compact environments.

“This year at Automatica, we’re highlighting the full capabilities of our THE series SCARA robots – including ceiling-mounted, ISO Class 4 cleanroom and IP65-rated models,” said Nigel Smith, CEO of TM Robotics. “These options allow the THE series to meet a wide range of application requirements – from space-saving installations to stringent hygiene and environmental protection standards.”

Also on display will be the Infinifeed advanced feeding solution. Designed by Terra Automation and integrated by DOMA automation, the system is powered by a Shibaura Machine THE600 SCARA robot and offers seamless part feeding and sorting to streamline production lines.

Infinifeed combines high-speed vision processing with precise robotic handling to deliver unmatched flexibility and reliability in feeding a wide variety of parts – significantly reducing downtime and enhancing overall workflow efficiency. Its compact footprint and modular design make it ideal for manufacturers seeking scalable, intelligent automation systems.

Shibaura Machine and TM Robotics experts will also be on hand to discuss the full capabilities of its 6-axis robot ranges. They include the TV series, offering high-speed flexibility for complex handling tasks; the compact, space-saving TVL range for efficient assembly and handling; and the lightweight, cost-effective TVM models designed for streamlined production. These robots are compatible with a wide range of applications, including assembly, inspection and integration with CNC and injection moulding systems.

“Automatica 2025 is a key platform for demonstrating the depth of our robotic offering,” continued Smith. “It’s a chance to showcase how Shibaura Machine’s technology, combined with TM Robotics’ distribution, integration and support, delivers integrated automation solutions built on Japanese engineering excellence.”

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Developed by Shibaura Machine, formerly known as Toshiba Machine, the THE series of SCARA robots has become a gold standard in high-speed, precision automation. Designed to meet the evolving demands of industries such as electronics, pharmaceutical, medical, cosmetics and automotive component assembly, each robot in the series provides exceptional cycle times, payload handling and trajectory accuracy.

At Automate 2025, the company will display all four models from the range: the THE400, THE600, THE800 and THE1000.

The compact THE400 is ideal for fast, precise operations in assembly and inspection processes, particularly within the electronics and automotive sectors. With a maximum payload of 5kg and a cycle time of just 0.39 seconds (with a 2kg load), the THE400 offers impressive speed and accuracy in a compact footprint – ideal for limited workspace environments.

Building on the capabilities of the THE400, the mid-range THE600 brings enhanced performance for heavier loads and more demanding applications. Offering 60 per cent higher payload capacity compared to similar SCARA robots in its class, the THE600 delivers powerful performance at an accessible price point. It was the first model in the series to be introduced with Shibaura Machine’s TS5000 controller – a next-generation platform designed with Industry 4.0 readiness, predictive maintenance, edge computing protocols and integrated AI diagnostics.

For applications requiring greater arm reach and payload capacity, the THE800 provides a strong balance of power and speed. It supports a maximum payload of 20kg with an improved cycle time of 0.41 seconds and has been engineered for precision motion control with a redesigned mechanical structure. This model is ideal for customers looking to automate medium-duty handling, packaging or inspection tasks with increased reach and flexibility.

As the largest model in the range, the THE1000 will be demonstrated live at the show, executing a high-speed movement sequence while carrying a 20kg payload – a clear illustration of the robot’s exceptional balance of strength, speed and control. With a 1000mm arm reach, cycle time of 0.44 seconds and compatibility with the TS5000 controller, the THE1000 is perfectly suited for tasks such as electric vehicle battery assembly, large-scale pick-and-place and other high-throughput applications.

Nigel Smith, CEO of TM Robotics, emphasised the strategic importance of showcasing the full range of capabilities at Automate 2025. “Our goal at Automate is to show how Shibaura Machine robots can be the backbone of a complete automation strategy – whether you’re integrating one robot or building a full robotic cell.”

In addition to the SCARA robots, TM Robotics will also demonstrate the TVM1200, a 6-axis vertically articulated model from the TVM series. This robot features a reach of 1418mm and a payload capacity of 15kg, making it ideal for integration with auxiliary manufacturing systems such as injection moulding machines, die casting units and CNC equipment.

“The THE series and TVM series reflect Shibaura Machine’s continued investment in intelligent, future-ready automation solutions. By combining performance with reliability and ease of integration, these robots give manufacturers the confidence to scale and adapt as demands evolve,” added Smith.

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Developed by Shibaura Machine, formerly known as Toshiba Machine, the THE series of SCARA robots has become a gold standard in high-speed, precision automation. Designed to meet the evolving demands of industries such as electronics, pharmaceutical, medical, cosmetics and automotive component assembly, each robot in the series provides exceptional cycle times, payload handling and trajectory accuracy.

At Automate 2025, the company will display all four models from the range: the THE400, THE600, THE800 and THE1000.

The compact THE400 is ideal for fast, precise operations in assembly and inspection processes, particularly within the electronics and automotive sectors. With a maximum payload of 5kg and a cycle time of just 0.39 seconds (with a 2kg load), the THE400 offers impressive speed and accuracy in a compact footprint – ideal for limited workspace environments.

Building on the capabilities of the THE400, the mid-range THE600 brings enhanced performance for heavier loads and more demanding applications. Offering 60 per cent higher payload capacity compared to similar SCARA robots in its class, the THE600 delivers powerful performance at an accessible price point. It was the first model in the series to be introduced with Shibaura Machine’s TS5000 controller – a next-generation platform designed with Industry 4.0 readiness, predictive maintenance, edge computing protocols and integrated AI diagnostics.

For applications requiring greater arm reach and payload capacity, the THE800 provides a strong balance of power and speed. It supports a maximum payload of 20kg with an improved cycle time of 0.41 seconds and has been engineered for precision motion control with a redesigned mechanical structure. This model is ideal for customers looking to automate medium-duty handling, packaging or inspection tasks with increased reach and flexibility.

As the largest model in the range, the THE1000 will be demonstrated live at the show, executing a high-speed movement sequence while carrying a 20kg payload – a clear illustration of the robot’s exceptional balance of strength, speed and control. With a 1000mm arm reach, cycle time of 0.44 seconds and compatibility with the TS5000 controller, the THE1000 is perfectly suited for tasks such as electric vehicle battery assembly, large-scale pick-and-place and other high-throughput applications.

Nigel Smith, CEO of TM Robotics, emphasised the strategic importance of showcasing the full range of capabilities at Automate 2025. “Our goal at Automate is to show how Shibaura Machine robots can be the backbone of a complete automation strategy – whether you’re integrating one robot or building a full robotic cell.”

In addition to the SCARA robots, TM Robotics will also demonstrate the TVM1200, a 6-axis vertically articulated model from the TVM series. This robot features a reach of 1418mm and a payload capacity of 15kg, making it ideal for integration with auxiliary manufacturing systems such as injection moulding machines, die casting units and CNC equipment.

“The THE series and TVM series reflect Shibaura Machine’s continued investment in intelligent, future-ready automation solutions. By combining performance with reliability and ease of integration, these robots give manufacturers the confidence to scale and adapt as demands evolve,” added Smith.

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1. Energy-saving by design

Optimising energy efficiency is one of the most effective ways to make robots more sustainable. In high-speed manufacturing, even marginal reductions in power usage can translate into significant savings over time.

One way robotics engineers are tackling this is by refining how robots move. Shibaura Machine took this approach when designing its latest series of SCARA robots, the THE800 and THE1000. Advanced motion control algorithms were created by engineers to fine-tune acceleration and deceleration, reducing unnecessary energy spikes while keeping operations smooth and precise. The principle is simple but powerful: move smarter, use less energy.

Weight is another major factor. Heavier robots require more power to move, so reducing mass is a straightforward way to improve efficiency. With this in mind, Shibaura Machine designed the THE800 to be 30 kg lighter than its predecessor, the TH850A, without compromising strength. Less weight means less power needed to get the job done – a win-win for both sustainability and performance.

Optimising torque performance is another important consideration. Shibaura Machine used a simulation process to accurately predict torque fluctuations of the THE800 model during various stages of motion. The study identified areas where efficiency could be improved, leading to enhanced motor control and smoother motion profiles. The findings demonstrated how adjusting acceleration and deceleration curves could minimise unnecessary torque peaks, reducing mechanical stress and improving overall efficiency.

2. Reimagining robot materials

Sustainability in robotics isn’t just about energy use, it starts at the very first stage of design. That means carefully considering the materials used in construction.

Traditionally, industrial robots are built from a mix of metals and plastics, some of which have a high environmental footprint. However, as manufacturers aim to reduce their Scope 3 emissions – which cover the environmental impact of their supply chain, from material sourcing to end-of-life disposal – there’s growing pressure to make smarter choices.

Engineers are now prioritising recyclable materials and finding ways to cut waste during manufacturing. Shibaura Machine has addressed this challenge by using one-dimensional computer-aided engineering (1DCAE) simulations during the latest SCARA development, allowing designers to refine robot structures before production. The result? Less material waste and a more efficient build.

Another crucial aspect is simplifying the architecture of the robot. The fewer components used, the less raw material is needed and the easier the robot is to manufacture, maintain and eventually recycle. The THE800 and THE1000 were developed with streamlined assembly in mind, reducing production waste while maintaining durability and performance.

Similarly, Shibaura Machine engineered the latest TS500-MS robot controller to be 33 per cent lighter than its predecessor, the TS3100. This was achieved through strategic downsizing, material selection and improved connector placement.

3. Building to last

A truly sustainable robot isn’t just designed for efficiency, it must also be built to last. Frequent maintenance and part replacements don’t just drive up costs for the end user; they also generate waste. That’s why modern industrial robots are engineered with longevity as a priority.

This has always been part of Shibaura Machine’s robot design philosophy, but the SCARA THE800 and THE1000 take it a step further by prioritising enhanced trajectory accuracy and structural rigidity. Engineers found this approach could significantly reduce wear and tear over the robot’s lifespan.

High-quality materials in critical joints and motors also play a role in extending operational life, ensuring robots can handle years of continuous use without excessive degradation. Meanwhile, advanced controllers help smooth out movements, reducing strain on components and minimising the risk of failure. The goal is to ensure the customer will undertake fewer repairs, experience less downtime and ultimately retain the robot for longer.

Evaluating sustainability efforts

Shibaura Machine assessed the environmental impact reductions of the THE SCARA robots using a life cycle assessment (LCA). The study compared the total energy consumption of the THE800 against its predecessor, the TH850A, revealing a 12.9 per cent decrease in electricity use at full load.

When factoring in a 77.7 per cent reduction in total oil consumption and a 39.5 per cent decrease in overall mass, the assessment confirmed an expected 12.8 per cent reduction in total life cycle CO2 emissions.

Sustainability is no longer an afterthought in robotics design, it is a fundamental principle. As industries demand greener solutions, manufacturers must rise to the challenge by creating robots that are not just powerful, but responsible. The goal isn’t just to build machines that work faster, but to design automation that works smarter – for both manufacturers and the planet.

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The end user, an Italian company called Centrostyle, manufactures a broad range of eyeglass cleaning cloths. The decoration of these items involves either pad-based printing machines or a process known as sublimation – a method of applying heat and pressure to transfer dye onto different materials.

Centrostyle’s challenge related to the handling of these cloths following printing. Once printed, Centrostyle wrapped its decorated cloth patches in 220 cm-high reels weighing up to 50 kg. Handling these reels was not only a time-consuming process; but also created health and safety concerns, risking musculoskeletal disorders to crush injuries. What’s more, in addition to handling the reels, workers had to manually detach the individual cloths from the paper roll, stack them and package them. This labour-intensive process translated into significant costs for Centrostyle.

Centrostyle needed an automated solution. The company tasked Roboprint, an Italian start-up, with developing an automatic system for detaching and stacking the cloths. Roboprint turned to specialist robotics and automation consultant and distributor BBS ROBOT, who provided robots programming support through its Robotics Engineering Center. BBS Robot was then able to specify a solution supplied by TM Robotics’ Italian distributor Tiesse Robot. Here, the collaboration between Roboprint and Japanese robotics manufacturer, Shibaura Machine, began.

Getting a grip on automation

Roboprint designed and developed a new customised solution based on its flagship printing head technology. The Splitter, which is currently patent pending, consists of a reel-dragging system that automatically pulls and folds the paper roll at an acute angle, allowing the cloth patches to be detached by approximately four mm. A second conveyor belt then takes over the patches, completely detaching them from the paper substrate. From here, robots get a grip of the process.

The patches are fed to two THE600 SCARA robots from Shibaura Machine. The THE600 is the second largest model from Shibaura Machine’s extensive THE robot series – a leading SCARA range designed and engineered in Japan.

Roboprint fitted the robots’ gripping hands with software-adjustable suction channels to collect the cloths one by one and stack them. These channels consist of perforated surfaces and are programmed to match the five cloth sizes produced by Centrostyle. Users can quickly select the desired cloth size on a PLC and the Splitter automatically activates the correct suction area in the perforated surface, collecting each cloth seamlessly.

The last step involves two conveyor belts that automatically collect stacks of patches that can then be boxed safely by an operator, eliminating manual handling hazards.

Smooth robot installation and operation

The Shibaura Machine THE600 SCARA robots were instrumental to the project’s success. These robots meet growing demand for fast-cycle automation, delivering optimal synchronised control and tracking precision. Despite its compact design, the THE600 has 60 per cent higher payload capacity than competing SCARA models in the same price range, making it the price-to-performance leader.

“Our Splitter system required a best-in-class robotic solution with best-in-class performance in terms of speed, precision and life span,” explained Valter Scolaro, R&D manager and owner at Roboprint. “The THE600 robotic arms supplied by Shibaura Machine distributor, TM Robotics met our expectations. They were easy to install and have operated reliably, at the correct speed, preventing vibrations and overvoltage.

“With two four-axis SCARA robots working in parallel, the Splitter system can cover the desired work area while achieving high throughput and maximum safety, with the robots constantly communicating to prevent collisions” continued Scolaro.

A critical component of the robotic solution is the TS5000 robot controller from Shibaura Machine. This device features dedicated edge computing protocols combined with vibration analytic tools, generating predictive maintenance profiles unique to each application. Thanks to these capabilities, the TS5000 reduces downtime to a minimum.

Intuitive software

In addition to the new generation robot controller, Roboprint was appreciative of the TSAssist industrial robot programming tool. “The TSAssist software is very intuitive and enabled us to adapt the firmware on the PLC to ensure seamless communication with the robots,” explained Scolaro. “TM Robotics’ technical support team, which we were able to access thanks to our precious collaboration with BBS ROBOT’s robots programming support team and Tiesse Robot, was helpful and responsive, which translated into a smooth programming experience.”

TSAssist is a flexible and user-friendly programming tool that provides powerful assistance to all phases of automation, from planning and installation to enhancement. Users can upload and download program and parameter files, generate 3D simulations and perform checks while benefitting from updated graphical user interface. Programmers can also import their CAD files when building a 3D simulation of a work cell being designed.

Eye-catching results

Thanks to Roboprint’s solution, Centrostyle has achieved sizeable efficiency and productivity gains, reducing its yearly operating costs and saving over €300,000.

“Unlike sectors like automotive and logistics, robots are yet to be widely adopted in the printing industry,” commented Nigel Smith, CEO at TM Robotics. “Our collaboration with Roboprint, made possible by our Italian distribution Tiesse Robot and BBS ROBOT, demonstrates how industrial robots can help automate printing heads and other printing devices, driving efficiency and productivity and reducing cost throughout the supply chain.”

Shibaura Machine SCARA robots can support multiple printing and stamping applications, including injection moulding.

Roboprint plans to build on the success of the Splitter solution to continue collaborating with TM Robotics through BBS ROBOT and Tiesse Robot. “The technical support and service provided by TM Robotics has been outstanding. They always answer our questions with clear and competent answers,” concluded Scolaro. “We look forward to continuing this successful collaboration, living up to our promise to bring automation and robotics to the printing sector.”

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By positioning the robot on the ceiling, manufacturers can free up valuable floor space, allowing other equipment to be accommodated in the same area. This can be particularly beneficial in facilities with limited space and for manufacturers looking to create more streamlined production layouts. Ceiling-mounted configurations also help to reduce potential obstructions and improve operator safety in busy environments.

Known for speed, precision and flexibility, Shibaura Machine’s THE series of SCARA robots is ideal for assembly, pick-and-place tasks, material handling and inspection processes. The range includes four models: THE400, THE600, THE800 and THE1000. With varying payload capacities and reaches, these robots provide unmatched performance, ensuring precision and efficiency for even the most demanding applications.

The THE400 is compact and offers a maximum payload of 5kg, excelling in high-speed operations, making it perfect for electronics and automobile component assembly. The THE600 builds on this with a higher payload of 12kg, offering 60 per cent more capacity than competing models in its class.

The THE800 handles payloads up to 20kg and offers a high-speed cycle time, making it ideal for demanding inspection tasks. The THE1000, the largest in the series, features a 100mm arm reach and a maximum payload of 20kg, making it well-suited for larger component assembly, including electric vehicle battery production.

Engineered to endure the demands of industrial environments, the THE series combines durability with functionality. It delivers incredibly fast cycle times and remarkable accuracy, enabling businesses to enhance productivity while maintaining the highest levels of quality. Compatible with the advanced TS5000 controller and TP5000 teach pendant, the THE series also offers seamless IoT integration, intuitive operation and real-time monitoring for improved control and efficiency.

THE SCARA robots are a popular choice in industries like electronics, automotive and pharmaceuticals. The new ceiling-mount feature allows manufacturers from all these sectors to reap these benefits, without compromising on floor space. Shibaura Machine’s new ceiling-mounted SCARA robots represent a forward-thinking approach to industrial robots, helping businesses to stay competitive in an increasingly automated world.

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The inherent risk of human error, potential contamination and the demands of regulatory compliance place considerable pressure on packaging operations in life sciences and related industries. Moreover, manual processes often struggle to maintain the precision, speed and consistency required to meet market demands. Traceability concerns and the complexities of quality control present further drawbacks. With the industry demanding high throughput and agility, automated packaging solutions offer an ideal solution.

To address the shortcomings of manual packaging in these sectors, Questt, a South American partner of global robotics supplier TM Robotics, has developed a market-first automated solution. Driven by the need for smarter, faster and more accurate vial packaging, Questt designed its QPack-1 robotic packaging machine as a complete solution.

Enhancing operations with industrial robots

Questt’s QPack-1 machine uses both six and four-axis industrial robots to package vials using continuous movement and automatic feeding. This monobloc turnkey machine system integrates two robots in a single unit, each performing distinct tasks, and the machine has a small footprint, allowing it to be integrated even into smaller spaces.

Operators can program the machine to package a predefined number of vials into a custom thermoformed transparent plastic box. The first robot positions the box in the workspace, while the second transfers vials from the production line using a vacuum attachment to fill it. As pharmaceutical products are also required to come with an enclosed brochure, the first robot can insert this brochure before the box is closed and it moves to the next stage of the production line.

TM Robotics supplies the two robots used in the machine. Both are from Japanese robot manufacturer, Shibaura Machine, formerly known as Toshiba Machine. The first, a TVL700 six-axis robot, is lightweight and vertically articulated, designed to optimise productivity in handling and assembly applications. With a reach of 700mm and a 4 kg payload, it offers exceptional versatility.

In the Questt monobloc packaging machine, its speed and accuracy enable efficient box loading and unloading in the workspace. The second robot, a THL400 SCARA robot, has an arm length of 400mm and a payload capacity of up to 5 kg, allowing it to handle varying vial quantities as needed. With cycle times of 47 seconds, it completes tasks swiftly and precisely, meeting the demands of a busy production line.

Boosting productivity with smarter processes

The Questt QPack-1 packaging machine addresses one of the most pressing drawbacks of the manual packaging processes – inconsistent and inefficient throughput. In one production line, the machine was found to be able to package up to 7,200 vials in an hour. When the same process was carried out manually, workers packaged around 2,000 vials in an average working day, highlighting the significant productivity improvement when automating this process.

The QPack-1 also uses cutting-edge pneumatics from Festo and a highly intuitive Siemens programmable logic controller (PLC) to oversee packaging operations. It offers a user-friendly interface and touchscreen capability, enabling easy process adjustments and real-time performance monitoring. The PLC’s simplicity streamlines programming, requiring minimal experience to operate the system. Coupled with the machine’s relatively straightforward installation and setup, integration into an existing production line is remarkably straightforward, despite the advanced robotics involved.

The Siemens system further enhances process traceability and reliability by using advanced technology to detect errors and respond promptly. Equipped with sensors and cameras, it identifies missing or misplaced products, or faults in the industrial robots. Upon recognising a fault, the system issues a warning and halts production until the operator addresses the issue, immediately allowing potential problems to be recorded for traceability and resolved with minimal downtime or further impact on production.

Production processes in life sciences, pharmaceuticals and veterinary manufacturing are also subject to stringent regulatory frameworks to ensure safety, efficacy and quality of all products. Given the nature of these industries, complete transparency and validation are imperative. The QPack-1 is CE-certified, and additional validation can be conducted to meet required medical industry standards, including Installation Qualification (IQ), Operational Qualification (OQ) and Performance Qualification (PQ), ensuring that the machine operates as intended.

The next generation of packaging systems

To further improve on this offering, Questt is currently developing an advanced solution that builds upon the current capabilities of the QPack-1 packaging machine. At present, the machine loads vials into separately manufactured pre-formed blister packages. Questt’s new machine will integrate packaging production into the same unit for a fully cohesive solution.

Through the incorporation of a thermoforming unit, the next iteration of the machine will produce the box, fill it with vials and heat-seal the package, enabling the entire process to be completed in-house. Using a single solution will save time, reduce costs and enhance overall productivity. Additionally, sealing the packages will allow any damage or tampering to be easily detected before distribution.

The limitations of manual packaging in the life sciences industries are evident, but the Questt QPack-1 robotic packaging machine effectively addresses the inefficiencies and inconsistencies associated with manual packaging.

By incorporating industrial robots, advanced technology, and an intuitive PLC, this automated system significantly improves precision, speed and traceability. The solution offers an ideal alternative to manual packaging that not only enhances productivity but also aligns seamlessly with the industry’s commitment to quality, safety and compliance.

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