GMPack Streamlines High Mix Packaging with Universal Robots Collaboration

Contract manufacturing in the healthcare and cosmetics sectors requires the handling of diverse container formats and strict adherence to hygiene standards. GMPack manages the filling and packaging of a wide range of custom products. As the variety of product formats expanded, several production steps—including container handling, capping, and sections of the filling process—continued to rely on manual labor.

This reliance on manual operations limited the company's ability to scale production capacity efficiently. It also introduced risks regarding product quality consistency and hygiene compliance. Additionally, managing operational costs and staffing for highly repetitive, monotonous packaging tasks presented an ongoing operational challenge.

Scalable Automation with Coordinated Robots
To address these capacity constraints and quality risks, GMPack implemented a tailored automation system developed in collaboration with the integrator Technicon. The chosen technical solution consists of three modular cream filling units designed to integrate into the existing production environment without causing operational disruptions.

Each modular unit utilizes two UR7e collaborative robots working in a coordinated workflow. Within each module, the first robot handles the precise picking and positioning of empty containers, while the second robot applies caps and positions the finished products. The systems also feature integrated printers to maintain batch traceability throughout the filling and packaging process.

Collaborative robot technology was selected due to its compact footprint and safety features, which allow the units to operate alongside human workers without the need for extensive safety fencing. Furthermore, the robots feature interchangeable grippers, enabling operators to switch between different container types and formats rapidly without complex reprogramming.

Operational Consistency and Increased Capacity
The deployment of the modular robotic system stabilized the packaging process by removing human variability from the handling and capping stages. The precise, repeatable positioning of the robotic grippers reduced manual errors and improved overall process stability, ensuring strict hygiene control.

"The UR cobot solution has increased consistency and reduced variability, giving us a more predictable production process and better control over quality," states Christian T. Kjærgaard, CEO of GMPack.

The automation of these repetitive tasks allowed the manufacturer to expand its production capacity and manage high-mix, customer-specific runs without increasing headcount or operational complexity. The modular architecture provides a scalable foundation, allowing individual units to be expanded or redeployed to accommodate future product variants and changing market demands.

Edited by Evgeny Churilov, Induportals Media - Adapted by AI.

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