ERN Laboratories, a pharmaceutical company with over 80 years of experience and a strong market position. It is an independent laboratory andbecause the vast majority of the medications it works with are its own. It covers all phases of the drug process, from development and manufacturing to marketing. Currently, ERN Laboratories isamong the 25 most important laboratoriesthat operate in Spain.
To maintain this trajectory, the company has had to significantly improve its production processes, such as with the incorporation of Packfeeder compact bottle positioners. This collaboration, which began in 2019, represents a clear example of how our equipment can successfully adapt to highly demanding environments, especially when available floor space is limited.
The challenge: to automate in an extremely small space
The main challenge for ERN Laboratories was to simultaneously automate three packaging lines within a plant with a very restrictive layout. The lack of available space prevented the installation of conventional equipment, so the project required a solution capable of combining high performance with an extremely compact design.
Furthermore, the client needed to guarantee precise handling of small containers, maintain the strict quality and hygiene standards of the pharmaceutical industry, and ensure that the integration of the equipment would not affect ergonomics or the existing production flow. In this context, the choice of compact bottle unscramblers was not just an option, but a key necessity to achieve automation without completely redesigning the plant.
The solution: Micra 100 compact bottle unscramblers
To address this challenge, Packfeeder developed a fully customized solution based on the installation of three In-Line Micra 100, one of the most efficient compact bottle unscramblers for space-constrained pharmaceutical applications. Thanks to their optimized design, these units were seamlessly integrated into the existing layout, enabling line automation without the need for structural modifications.
One of the most notable elements of the solution was the incorporation of an ionized air cleaning system in one of the units. This system removes particles from the containers before filling. It ensures the hygiene standards required in the pharmaceutical sector without the need for additional equipment. Integrating this additional function into one of the unscramblers helps maximize space efficiency.
Furthermore, the equipment was configured to offer high flexibility in handling different formats of small bottles, facilitating quick format changes and ensuring precise and gentle handling of the containers. This adaptability is especially relevant in environments where product variety is high and changeover times directly impact productivity.
Results: maximum efficiency in minimum space
The project implementation was a complete success, enabling ERN Laboratories to transform three of its production lines without expanding its facilities. The integration of the compact bottle unscramblers significantly reduced the machinery footprint, improved workflow, and increased overall process efficiency.
Furthermore, the integration of the cleaning system helped to enhance the quality of the final product, while the automation of the lines optimized resources and reduced manual intervention. This project demonstrates that, even in environments with severe space limitations, it is possible to achieve high levels of performance with the right technological solutions.
Long-term collaboration
Since 2019, Laboratorios ERN has maintained a trusted relationship with Packfeeder based on the reliability of its bottle unscramblers, their adaptability, and their specialized technical service. This collaboration continues to evolve with the incorporation of new packaging formats, demonstrating the flexibility of the equipment and the shared commitment to continuous improvement.
This success story solidifies Packfeeder’s position as a leader in the design and integration of compact bottle unscramblers for the pharmaceutical industry, particularly in projects where floor space is a critical factor. Its ability to offer efficient, flexible, and highly integrable solutions makes it a key technology partner for companies seeking to optimize their production lines without compromising performance.
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