A long-standing automation partnership between a Swiss machine builder and one of the world’s leading manufacturers of industrial robots is aiming to help transform the pharmaceutical supply chain in Europe with the launch of what is believed to be the ‘smallest’ automated palletising cell for vials and pre-filled syringes.

Swiss-based Robotronic has partnered with Mitsubishi Electric’s Factory Automation EMEA division for more than two decades. Now, the two organisations are collaborating together on a new low-footprint cell to help the pharmaceutical industry overcome record-high shortages across Europe in recent years for medicines ranging from children’s cough syrups through to antibiotics and even cancer treatments.

The growing demand, which has impacted patient treatment and quality of life, has led the European Medicines Agency to increasingly focus on one of the main causes of shortages – manufacturing and quality issues – with the aim of ultimately strengthening the fragile pharmaceutical supply chain.

Mike Weber, founder of Robotronic, says faster production is required to shorten lead times and cope with the ever-increasing demand. “We are a Swiss company concentrating on machine building with robotic applications for the pharmaceutical industry, including everything from de-nesting and re-nesting, through to de-traying, re-traying, and palletising. We have specific expertise in vial and pre-filled syringe handling, offering solutions that deliver maximum efficiency with a small footprint, and enabling pharmaceutical manufacturers to rise to the challenges in their supply chain.”

One of the key challenges for Robotronics is compliance. “Pharmaceutical consistency is about more than quality,” says Mike. “It is also about regulatory compliance and safety.

“To get the required productivity, we need two robots working very closely together at high-speed, but we also need the assurance that the delicate products being handled will not be damaged in the process.”

The Robotronic choice is Mitsubishi Electric, specifically the FR series, a highly flexible robot with compact arm sizes that is equipped with SoftTouch technology.

The result is a small footprint automation solution with increased productivity for handling pallets as small as 120cm x 80cm. Most importantly, the FR series has built-in compliance control that offers soft touch capability that delivers zero product damage with no glass-to-glass contact, no broken glass and is easy-to-clean.

“The challenge was to have two robots operating side by side in a confined environment without compromising speed or precision,” says Mike. “With Mitsubishi Electric’s help, we have two robots driving at full speed within millimetres of each other with no possibility of collision. This enables our cells to process up to 600 products a minute, without really challenging the robots.”

He concludes: “The relationship between Robotronic and Mitsubishi Electric is a true technological partnership – a combination of deep pharmaceutical process expertise allied to best-in-class robotic technology. Together, we believe we can develop machines that can shorten lead times and create a more robust pharmaceutical supply chain.”

Stefan Knauf, Division Manager at Mitsubishi Electric Factory Automation – German Branch, adds: “The biggest challenge was enabling Robotronic to safely and continuously operate two robots side-by-side in a confined environment, without compromising speed or precision. Our FR series robots with additional servo axis perfectly matched their requirements to deliver high throughput from a small footprint.

“The unique, built-in compliance control also allows the robots to gently handle glass vials without the risk of damage. Ultimately, in pharmaceutical production, consistency isn’t just about quality, it is about regulatory compliance and safety. Our relationship with Robotronic is a true technological partnership. Mike and his team bring deep pharmaceutical process expertise and we bring robotics innovation.”

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Bhavnita explains why companies must adopt these technologies now, despite barriers like cost and legacy systems. She looks at where these tools can be applied across operations, and how they enable a shift in workforce roles from repetitive tasks to more value-adding activities.

The session outlines who within the business must be involved for successful implementation, and when to begin, especially for those aiming to harness AI and build future-ready, resilient operations.

High productivity and flexibility are key competitive advantages in times of digitalisation. With SICK as your partner, you benefit not only from one of the world’s largest networks of experts for functional safety, but also from a comprehensive range of safety solutions that ensure personal safety and efficient processes.

The SICK safety portfolio includes safety controllers, safety switches, safety distance sensors, safety laser scanners, safety radar sensors, safe series connection, safety relays and safety multibeam scanners, and the company has the ability to provide complete safety systems.

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Within its “Identification and Access Management” portfolio, Pilz offers a comprehensive range of products, solutions and software for the implementation of both safety and security tasks.

These cover applications from simple authentication to complex access permissions, and access management through to safe operating mode selection, maintenance safeguarding and safeguarding of data and networks.

One such solution is the ‘key-in-pocket’ maintenance safeguarding system for protection against unauthorised restart. This solution ensures that a machine cannot resume operation while people are still in the danger zone. The key-in-pocket maintenance safeguarding system is designed for machines with danger zones, which are protected by a safety fence and which employees need to access – robot cells for example.

In comparison with conventional lockout-tagout (LOTO) systems, maintenance safeguarding with the Key-in-pocket solution is implemented via RFID keys with corresponding permissions and a safe list in the Pilz controllers. As a result, it provides purely electronic restart protection and makes mechanical interlocking devices and warning tags redundant.

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Mechatronics combines many product types and engineering disciplines to create a complete solution. It focuses on integrating these areas to improve the functionality and efficiency of manufacturing processes that are essential in meeting rapidly changing demands on machine builders.

Mechatronics solutions are flexible and intelligent, capable of manufacturing different product types.

In his presentation, Jason explores the global mega-trends that are driving rapid and unpredictably changing manufacturing and consumer demands. He explains how machine builders must deliver machine and lines to meet these demands to compete in their own market space. He also looks at the importance of IT/OT and cyber-security in realising a digitally connected machine.

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He highlights the picking of fresh fruit, with a particular demonstration on the stand showing a robot picking up oranges. “We work with a lot of fresh produce, and one of the challenges is that it’s organic – different shapes and forms the whole time,” he says.

The technology combines 3D vision technology with AI to adapt and react to those changing forms. “We’ve got some clever deep learning that can decide if it’s an orange we do want to pick or don’t want to pick,” he adds.

OAL helps food manufacturers on their automation journey with cutting-edge solutions including autocoding, label verification and bespoke robotic systems. OAL’s strong experience in the food industry has helped it to spot trends and stay ahead of the curve, with automation technology that can radically improve productivity, food safety and traceability in food processing.

OAL’s desire to transform the food manufacturing industry is supported by forward-thinking companies across the globe and the UK government, which has funded projects valued at £4.5 million.

At Machine Building Live, IDS highlighted everything from open modules to fully embedded inspection systems, with a live demonstration of object detection using AI. Also on show was a live streaming camera for use within a machine to record faults and events, which can be downloaded subsequently for analysis.

A further demonstration highlighted IDS’ capability in 3D imaging for applications such as robot pick and place, as well as in the medical industry in areas such as MRI scanners.

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In automated processes like polishing, grinding, linishing and deburring, robotic machines for surface finishing use tools such as belts, wheels or brushes to deliver consistent and accurate finishes. While fixtures securely hold the workpiece, the programmable control systems would direct the robot’s movements, ensuring accuracy and consistent quality.

These machines can present significant hazards when operators need to access for setup, adjustments, or troubleshooting. Risks include exposure to moving parts, unexpected start-up or an operator becoming trapped. Effective risk reduction measures are essential to protect people and prevent unplanned downtime.

A standout product that meets Intec’s requirements is the tGard range from Fortress Safety. With a slim 40mm profile, tGard interlocks can be mounted easily into narrow areas. In addition, the range’s compact design allows pushbuttons and other control elements to be integrated into a single unit, along with emergency stops and escape releases. Having all necessary controls in one location boosts efficiency for operators while reducing error potential.

Intec Robotics has implemented tGard across various configurations over the years, from simple locking bodies to more complex solutions. It was one of the first manufacturers to adopt the tGard HLC (High Level Coded) version to increase protection against defeat of the interlock and enable guard monitoring up to PLe thanks to having an RFID actuator.

Personnel keys were included in some of the company’s solutions to prevent unexpected start-up and operators from being trapped inside. By carrying these keys with them when performing tasks, machines wouldn’t be able to restart until the keys are returned and the guards are closed.

Roose Automation wanted to give its robot arm the freedom to move across multiple chocolate dispensers inside a compact vending unit. A standard 6-axis robot couldn’t cover the full range and integrating a linear axis often means weeks of additional programming.

With the ready-to-install 7th axis from igus, a robot’s working range is quadrupled, and it also connects directly to its controller with the company’s “plug-to-program” interface.

“In projects like ChocoMatic, it’s about simplicity,” says Adam Sanjurgo, Automation Product Manager at igus. “You install it, the controller recognises it, and it just works.”

The igus axis forms the backbone of the ChocoMatic system. Mounted beneath the robot, it allows precise horizontal movement over multiple trays, powered by a toothed-belt drive that delivers up to 0.6 m/s speed and ±0.3 mm positioning accuracy.

With the plug-to-program system, Roose Automation integrated the axis directly into the robot’s control software. No extra coding, no complex interface design.

The results have been impressive: weeks saved in development time; thousands of pounds saved in programming costs; and flawless operation and increased productivity.

The success of ChocoMatic goes beyond chocolate. It shows how smart, modular automation can unlock new applications for SMEs. The igus linear axis lets a single robot do more – serving multiple machines, workstations or products, all without sacrificing precision or control.

Each igus 7th axis supports robots up to 55 kg, runs on a lightweight aluminium rail up to 6 metres long, and includes lubrication-free polymer bushings and e-chains from igus for cable protection.

Now compatible with the latest robot models including Universal Robots UR 20, UR 30 and Fanuc CRX, the 7th axis is making long-reach automation faster and easier for companies everywhere.

“The ChocoMatic shows how our plug-to-program technology can help any company, not just in manufacturing.” says Sanjurgo. “Expanding a robot’s range used to mean extra engineering. Now it’s as easy as plug, play and produce.”

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As highlighted by ‘The Robot Queen’ and robotics expert Vanessa Loiola, the standard no longer uses the terms ‘collaborative robot’ or ‘collaborative operation’, emphasising that only the application can be designed, verified and validated as collaborative.

This reflects a major conceptual shift in how robotic safety is defined. The updated ISO 10218-1 and 10218-2:2025 standards now focus on a risk-based approach that encompasses the entire robot system, including the end-effector, workpiece, and surroundings. It also introduces more stringent guidelines for validation procedures, safety-rated soft axes and stops, and highlights the growing importance of safety integration during the design phase rather than post-deployment.

This change underscores the importance of comprehensive risk assessments and system-level safety validations over relying solely on robot labels. Safety is no longer just about the robot being ‘collaborative’ – it’s about the collaborative design of the entire application.

Your trusted partner for Techman Robot integration

As the authorised UK distributor and integrator for Techman Robots, LG Motion is at the forefront of delivering application-centric automation solutions. The company’s expertise and experience ensures that each deployment is tailored to meet specific safety and operational requirements, aligning with the latest industry standards, including the updated ISO 10218:2025.

Techman’s range of robots come equipped with built-in AI vision systems, enabling tasks such as quality inspection, pick-and-place, and assembly with high precision. A range of robots offering payload capacities from 5 kg to 30 kg and reach up to 1902 mm can cater to a huge range of applications across various industries.

With over 20 years of experience in the design and manufacturing of advanced motion control solutions, LG Motion is a trusted partner for businesses across science and industry. LG Motion’s deep engineering expertise, coupled with a commitment to precision and innovation, enables the company to deliver bespoke automation systems tailored to the most demanding applications. From cutting-edge research laboratories to industrial production lines, LG Motion’s solutions enhance performance, reliability and efficiency. By choosing LG Motion, you’re not just investing in high-quality products; you’re gaining a long-term partner dedicated to your success through technical excellence and outstanding customer support.

Comprehensive integration services: From initial consultation to full system integration, LG Motion provides end-to-end solutions that encompass mechanical design, control systems and safety validations including support.

Commitment to safety and compliance: LG Motion’s integration processes prioritise safety, ensuring that each application complies with the latest ISO standards and industry best practices, particularly in light of the 2025 updates.

Explore the Techman Robot range

Discover how Techman’s robots can enhance your operations by visiting LG Motion’s dedicated website: techman.lg-motion.co.uk. Here, you’ll find all the latest information on our product offerings, case studies and the various applications these robots can support.

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