The new version of the GMP specification puts forward higher requirements for the drug packaging process, and traditional packaging equipment is gradually showing signs of fatigue in terms of weighing accuracy and data traceability. A Chinese medicine preparation company once had a batch of products reworked due to differences in packaging volume, with direct losses exceeding 2 million yuan. The three-level linkage calibration system of the automatic metering and packaging machine, through the coordinated operation of the pressure sensor array and the infrared positioning device, stably controls the single-dose packaging error within ±0.5%, fundamentally eliminating such quality accidents.
The core equipment of the solution is equipped with a patented dynamic compensation system, which has three innovative features:
1. The environmental perception module monitors the changes in temperature and humidity in the workshop in real time and automatically calibrates the metering parameters every 15 minutes;
2. The 64-channel parallel metering unit achieves constant accuracy under continuous operation;
3. The blockchain evidence storage system fully records the packaging data of each batch, meeting the GMP electronic data integrity requirements;
In a vaccine production base in East China, the intelligent packaging matrix constructed by 6 networked automatic metering and packaging machines has increased the product filling rate from 98.3% to 99.9%, and the annual quality cost has decreased by 37%.
Aiming at the pain point of the narrow time window for production line transformation of pharmaceutical companies, the solution adopts a modular pre-installed delivery system. The key components complete a 72-hour aging test before leaving the factory, and the on-site installation adopts "guide rail positioning + laser calibration" technology to shorten the equipment deployment cycle to 60% of the traditional mode. A listed pharmaceutical company in Southwest China used this solution to simultaneously complete the upgrade of 3 production lines during the 12-day shutdown period, and resumed production 5 days ahead of schedule.
The MES system docking module of the solution transmits packaging data to the enterprise quality management platform in real time, forming a digital twin of the entire chain from filling to warehousing. After a certain biopharmaceutical company applied it, the OEE (overall equipment efficiency) of the packaging process increased by 22%, the quality traceability response speed increased by 85%, and more than 300 hours of preparation time were saved to meet the FDA audit.
In the metal shell of the automatic metering packaging machine, the coordinated operation of the precision gear set and the smart chip is writing a new standard for pharmaceutical packaging. When the operator taps the start button on the touch screen, it is not only the issuance of production instructions, but also the full activation of a complete set of quality assurance systems - this may be the most concrete footnote in the era of smart pharmaceuticals.
