Labelling and packaging 500 pens per minute: a compact revolution

A notable advancement in pen packaging technology is at the heart of one of IMA’s recent innovative projects, developed for a customer in the US. The goal of the project is: to create a line that combines maximum efficiency, gentle product handling, reduced footprint and high product control, improving performance.

The workflow covers the following stages:

1. RD6P by IMA BFB: unloading trays of pens from pallet
2. TLS by IMA BFB: unloading pens from trays (frame by BFB, integration by IMA Safe)
3. Labelling module by IMA Safe in cooperation with IMA Phoenix: labelling of pens arranged horizontally
4. DYNAMICA by IMA Safe: horizontal continuous cartoning
5. SENSITIVE AP400 CW by IMA Life: carton-labelling machine with 100% check-weighing system
6. CP38 by IMA BFB: side-loading case packer
7. RP4 by IMA BFB: palletizing system

Robotic tray unloading	Case overturning before pick-up by the robot

The core of the innovation

The breakthrough lies in bringing together different functions within a single, compact module provided by IMA Safe, functions that are traditionally performed by three separate machines. This module integrates:

1. TLS that unloads pens from trays and places them onto individual carriers – one carrier per pen.
2. IMA Phoenix labelling modules that apply labels to pens when still in the carrier, which not only transports the product but also actively orients and handles it during label application.
3. Robotic pen loading into the cartoner bucket chain

SENSITIVE AP400 Check weighing bottom view	SENSITIVE AP400 Top labelling head

This design ensures that pens maintain the same horizontal orientation throughout all stages, providing exceptionally gentle handling even at high speeds of up to 500 pens per minute. Furthermore, this optimises the efficiencies which are essential if you use separate machines, as it does not require loops and inaccuracies.

The heart is what is in between

The unique feature is the dual-track carrier transport system, paired with two Phoenix labelling modules per lane – four modules in total. This architecture delivers unmatched performance and flexibility:

• 250 pens/min: in an extremely compact set-up.
• 500 pens/min: by running both tracks in parallel for maximum output.
• Two different pen types in the same carton: with independent handling on each track.

In addition to its high speeds, this transport system delivers outstanding efficiency, as the product is always positively held in the correct position and orientation, while preserving its integrity and protecting it throughout the entire process flow.

Key advantages

• Speed: up to 500 pens/minute with precise labelling.
• Autonomy: automatic cartons loading system into the magazine
• Compactness: three functions integrated into a single module, reducing footprint and line length.
• Modularity: ability to operate in three different production modes.
• Gentle handling: maintaining the product’s orientation throughout all stages.
• Future flexibility: ready for developments involving syringes and other devices.

This new platform represents a unique combination of high performance, reduced footprint, and operational versatility. It offers a compact, high-productivity system with strong potential for future developments, ideal for those seeking innovation and line optimisation.

The project developed for the US also represents the remarkable advantage IMA Pharma has as a single-source supplier. Leveraging the experience belonging to each division and channelling it into an integrated solution is an approach that benefits the customer. This goes beyond the solution we supply to include all the necessary maintenance requirements or potential upgrades that may arise in the future. Just another reason to remind us that All-In-One is beyond doubt the best way forward.