Revolutionizing Syringe Production with Advanced Automation
In-Mold Labeling and SCARA Automation for Syringe Assembly
The world of manufacturing has long faced challenges: slow production times, inconsistent quality, and the pressure to meet rising demand with fewer resources. Manufacturers were caught in a cycle of trying to balance speed with precision, often leading to delays, waste, and increased costs. The problem was clear: traditional processes weren’t designed to keep up with the demands of modern syringe production.
The Goal: Increase Precision and Speed
When Natech began working with a pharmaceutical client seeking to produce and assemble syringes, our mission was clear: increase both precision and speed. The goal was ambitious—to develop a system that could drastically speed up syringe production without sacrificing the quality and reliability customers depend on. But the challenge went beyond speed. The client had reported receiving boxes from previous partners with missing or misapplied labels, unassembled parts, and part counts off by hundreds! These issues caused major inefficiencies and risked product integrity down the line.
To address this, the team set out to design a system that would tackle all of these pain points at once. They needed a way to integrate in-mold labeling directly into the molding process for consistent placement and traceability. Our team needed assembly automation with built-in checks to ensure every part was properly put together before packaging. And they needed a reliable way to count each part going into a box—accurately, every time.
So, the team focused on one core idea: integrate advanced automation into syringe production in a way that increases efficiency while ensuring accuracy and quality at every step.
The Solution: A Fully Integrated Automation Line
The result of this vision is Natech’s state-of-the-art automation system. Designed with speed, accuracy, and reliability in mind, the system combines two complementary automation cells working in sync.
The first is an in-mold labeling (IML) system that uses static and air pressure to position labels accurately in molds during the injection molding process. This approach drastically reduces cycle time by ensuring that once the plastic is molded, the labels are already in place and ready to go. The same robot that places the labels into the mold retrieves the molded parts, minimizing downtime and maximizing production speed. A vision camera system checks every part for label placement accuracy, rejecting any defective pieces automatically.
Next, Natech’s in-house assembly cell steps in. This system uses SCARA robots and vibration bowls to assemble syringe barrels with application tips and tip covers. An overhead camera verifies that each component is correctly placed and oriented. The part is immediately removed from the line. This critical step guarantees that customers will never face the headache of receiving unassembled parts. Watch the award-winning system in action:
Breaking Speed Records
One of the most impressive feats of the automation system is its incredible speed. Initially, the target was to achieve a cycle time of 3 seconds per unit. However, the final system achieved a 2.25-second cycle time, far surpassing expectations. This rapid pace was made possible by the precision and speed of the SCARA robots, which handle part positioning and assembly tasks with ease, keeping the entire system running smoothly and continuously.
In addition to speed, the system also incorporates advanced features like RFID access control for security and traceability. This feature allows for customized access levels, ensuring that only authorized personnel can access critical functions. Additionally, a box conveyor helps track part quantities entering packaging, addressing a long-standing concern where box counts were often off by hundreds.
A Bold Step Into the Future of Automation
What truly sets Natech’s automation system apart is the level of control it offers. With its integrated vision camera system, RFID access, and automatic rejection of defective parts, the system ensures that every syringe is assembled with the highest quality standards. The result is a product that meets customer expectations for both speed and precision.
Additionally, the system’s flexibility allows it to adapt to different needs—whether it’s speeding up production or accommodating changes in the production line, Natech’s solution provides unparalleled reliability. With this innovative system, customers can rely on fast, accurate, and consistent results, while manufacturers can enjoy increased efficiency and reduced costs. It’s a solution that delivers confidence—every part, every time.
Natech Plastics: A Comprehensive Manufacturing Partner
Natech Plastics is a contract development and manufacturing firm, located in Ronkonkoma, NY. Natech specializes in offering end-to-end services for clients in the medical device and diagnostics markets. Natech offers services in design, engineering, injection molding, assembly, filling and sealing, and packaging. Natech is certified ISO 9001, ISO 13485, and an FDA-registered facility, and operates an ISO Class 8 cleanroom.