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Robotic filling line with advanced servo control and MES integration

Discover how we implemented a robotic filling line with advanced servo control and MES integration for a global pharmaceutical manufacturer. Read the case study.

Industry

Pharmaceutical / Industry 4.0 / Robotics

Scope

Software (PLC, Robot, HMI, SQL) / Vision-Guided Robotics / MES Integration / Multi-Axis Servo Control

Timeframe

ongoing

Technology

  • Siemens TIA Portal V18 (Step7, WinCC Advanced)
  • Sinamics Startdrive V18 (Servo Control)
  • Stäubli Robotics Suite (SRS)
  • Microsoft SQL Server
  • Vision Processing (640x480 px)

0.15 mm

filling & capping precision achieved

15+

modules with integrated robotic, servo, and vision systems

100%

SAT success rate in pharmaceutical validation protocols

The client

A global pharmaceutical manufacturer operating under high sterility standards, requiring full digitization and automation of the medical media filling process.

Business needs

Automation of the critical process of filling and sealing medical packaging. The system had to ensure full traceability (batch tracking) through integration with the MES system and the highest mechanical precision when handling asymmetrical components to eliminate the risk of contact with strong toxins.

The challenge

  • 01

    Submillimeter positioning (0.1–0.15 mm) Insertion of an asymmetrically positioned elastomeric pump hole into a dispensing needle based on a low-resolution camera image (640x480 px).

  • 02

    Complex product manipulation Performing a precise process of unscrewing and screwing product caps using a servo axis, while maintaining strict torque values.

  • 03

    Dual-Product Handling Simultaneous picking up of two products, requiring the use of an additional, movable needle mechanism controlled in real time.

  • 04

    Dynamic data exchange Integration with the local MES system to retrieve batch-specific data and report production status.

Our solution

We implemented Vision-Guided Robotics (VGR) to compensate for product geometry deviations in real-time, achieving a 0.15 mm tolerance margin by bridging high-speed robotics with intelligent software.

  1. Advanced Motion Control

    Use of servo drives controlled directly from the PLC for precise control of the moving needle and product capping/decapping mechanisms.

  2. Intelligent Robotics and Vision

    Implementation of VGR (Vision-Guided Robotics) algorithms to compensate for geometric deviations of products or their parts.

  3. Vertical Integration (MES/IT)

    Development of a communication interface with the MES system, enabling automatic batch parameter retrieval.

  4. Precise Kinematics

    Optimization of the Stäubli robot's trajectory in an extremely limited working area (2-3 mm margins).

Technology used

  • Siemens TIA Portal V18 (Step7, WinCC Advanced)
  • Sinamics Startdrive V18 (Servo Control)
  • Stäubli Robotics Suite (SRS)
  • Microsoft SQL Server
  • Vision Processing (640x480 px)

The outcome

The project delivered a robust, future-proof production line that successfully passed rigorous SAT testing in the UK and is now in full-scale operation. By implementing a high-precision automated system and intelligent vision processing, we achieved a level of safety and accuracy that eliminates the risk of contamination and costly medium loss. The seamless integration with the existing IT ecosystem ensures that every single unit is accounted for, providing the client with the highest level of operational security and regulatory compliance from day one.

  • Full digitization
  • Extreme accuracy
  • Process reliability
  • Operational success

What we implemented

  • High-Precision VGR Precise positioning based on vision with low matrix resolution.
  • Servo-Controlled Capping Automatic capping and uncapping controlled by a servo from the PLC level.
  • Active Needle Control Movable dosing needle controlled by a servo drive for dual-product systems.
  • MES Batch Management Automatic handling of production batches retrieved from the MES system.
Jacek Fischbach
They said the hardware had its limits. We said: ‘Challenge accepted.’ Seeing a robot navigate the handling of highly toxic media with sub-millimeter accuracy using low-res vision is a testament to the Polish engineering spirit of finding a way when others see a dead end. It wasn't about having the most expensive tools; it was about having the right mindset to make them perform far beyond their spec sheets.
Jacek Fischbach — Delivery Executive

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