The pharmaceutical filling line is an easy-to-overlook but critical part of pharma operations. As straightforward as this process is, it presents a significant opportunity for optimization. The industry could become safer, faster and more cost-effective if more manufacturers embraced automation in this area.

How automation improves pharma filling lines

Automated pharmaceutical filling line systems have come a long way in a relatively short time. Capitalizing on this technology can boost the industry on several fronts.

Accuracy

One of the most important advantages of filling line automation is that it’s more precise than conventional methods. Humans are prone to mistakes, presenting a significant obstacle for pharmaceutical companies. Any errors could slow production or introduce quality control concerns. Automation minimizes these risks because machines cannot get distracted or tired.

A machine programmed to dispense a certain amount of fluid will deliver the same results every time. Machine vision fill sensors can similarly improve quality checks to catch any defects that make it through. This higher accuracy prevents costly regulatory penalties to maintain lower prices and wider drug accessibility.

Efficiency

Another benefit of filling line automation is that it’s far faster than manual alternatives. Modern liquid packaging machines can fill over 80,000 bottles an hour, sometimes exceeding 100,000 containers hourly. These figures come mainly from food and beverage applications, but pharmaceuticals use smaller packages, enabling even higher speeds.

Automated solutions can also combine multiple processes into a single workflow. Some facilities have run tank cleaning, transfers and sterilization at the same time to minimize downtime and increase output. As a result, pharmaceutical labs can meet rising demands despite ongoing labor challenges.

Safety

Pharmaceutical filling line automation is also safer than manual methods. Much of this safety stems from robotic systems never leaving the controlled lab environment. Unlike humans, they introduce no cross-contamination risks because they only contact surfaces in one work line. Eliminating these hazards ensures pharmaceutical products remain safe for use.

Automation’s other primary safety advantage is that labs can capitalize on microbe-resistant materials. Compounds like titanium dioxide can release free radicals under UV light, killing harmful microbes, and others—such as copper and silver—are naturally microbe-resistant. Building tool arms from these resources ensures easier, more effective cleaning than possible with human tissue.

Ongoing improvements

Introducing robots into the pharmaceutical filling process opens the door to easier long-term optimization. Ongoing improvements are possible in any setup, manual or automated. However, automated machinery has the advantage of creating recordable data points each time it operates. Pharma companies can use this information to highlight inefficiencies and find solutions.

Artificial intelligence (AI) can analyze workflow data to find trends, such as where quality issues stem from or where bottlenecks occur. More advanced predictive models can even simulate how various changes address these inefficiencies. As helpful as these technologies are, they require vast amounts of data to be reliable. Automation automatically produces this information as it works, enabling more effective AI applications.

Considerations for automated pharmaceutical filling lines

Pharma companies hoping to capitalize on these benefits should keep a few things in mind. First, 48% of U.K. organizations cite a lack of technical talent as their biggest barrier to automation—more than any other factor. Working with robots requires a different skill set than manual workflows, so businesses must prepare for disruption ahead of time.

There are two main solutions to this obstacle. One is to work closely with robotics companies to design and implement a user-friendly system that employees can adapt to. The other is to reskill the workforce in robotics-related fields, so automation is less disruptive. Combining both strategies will yield the best results.

Automation can also be expensive. Starting small and slowly automating more processes after the first shows a positive return will help. The increased efficiency will make up for the initial expenses over time. Pharma organizations should also look for robotics solutions that address their unique inefficiencies. Automating for automation’s sake will be of limited use, but more targeted upgrades can produce impressive changes.

Similarly, pharmaceutical filling line processes must use the right type of robot for the job at hand. Filling machinery varies by nozzle count, size, cost, volume and throughput. Pharma companies must understand their workflow needs and find one that fits them. 

Pharmaceutical filling lines need automation

Pharmaceutical filling lines may not be the most mission-critical workflow, but they are important, nonetheless. They are also comparatively easy to automate, making them an ideal target for innovation.

Automating these processes can produce far-reaching efficiency, safety and cost-saving benefits. Public health and medicine accessibility will improve as more pharmaceutical manufacturers take advantage of these benefits.

Emily Newton is the Editor-in-Chief of Revolutionized. She’s always excited to learn how the latest industry trends will improve the world. She has over five years of experience covering stories in the science and tech sectors.