Fully automated manufacturing cells – investments that pay off

Components for DNA analysis are multi-color printed in a fully automated process using elastic silicone rubber tampons.

The new magazine loader was painted in Wirthwein corporate design colors and is illuminated from the inside by a LED strip in the 4.5-meter-high glass tower. During the first run, Christoph Merhold, Global Key Account Engineer, and Tobias Heldmann, Automation Technician, will oversee the position monitoring of the handling system.

How can plastic systems be produced more efficiently and with higher quality? These questions are at the heart of daily operations at the medical technology company Wirthwein Medical GmbH & Co. KG. When dealing with high batch sizes, multiple production and assembly steps for complex components, the most effective and economical solution is often a fully automated manufacturing cell. The individual production steps are analyzed, condensed, and integrated into customized systems. Wirthwein Medical GmbH & Co. KG has significantly increased its know-how over the past years by raising the level of automation to meet the high demands in diagnostics, medical technology, and pharmaceutical industries.

There are many good reasons to automate manufacturing processes in medical technology. Besides the constantly increasing cost pressure, environmental influences on the production process are reduced. Automation also increases cost-effectiveness and enhances both the quality and safety of production processes. The plastic components are either produced in highly automated manufacturing cells with connected injection molding machines or assembled into modules in cleanrooms according to the assembly concept. The robot-assisted manufacturing cells or assembly lines pick, place, move, weld, print, cut, inspect, control, convey, and package during the production process.

Each project is planned individually and assigned to a technically and industry-experienced project manager. The specialists at Wirthwein Medical GmbH & Co. KG rely on proven and experienced system builders. Innovation plays a very important role in designing the system. Due to the complexity of production, the system builders do not use standard modules. Many mechanical assemblies need to be designed and manufactured individually. This is necessary to integrate the highly complex steps.

This year, Wirthwein Medical GmbH & Co. KG implemented three new assembly systems. When Christoph Merhold, Global Key Account Engineer, stands in front of the latest systems at the "An der Papiermühle" plant in Mühltal, he is very satisfied. "With the new systems, we are optimally prepared for the future with an even higher level of automation and secure our customers' reliable delivery even in extreme future events. The experiences from the Covid-19 pandemic have shown that a high level of automation can reduce the risk of contamination and quarantine-related employee downtime."

Automation including Printing

In one of the new fully automated manufacturing cells with an attached injection molding machine, plastic components for DNA analysis are produced. Originally, the parts were manufactured in a cleanroom and then manually printed. Due to the massively increased demand and the high quality requirements of the customer, Wirthwein Medical GmbH & Co. KG decided to automate this process for this project. Vision systems enable 100% quality monitoring, which is a significant advantage for the customer. The new technology also provides great relief for the employees at the machine. In addition to the injection molding process, handling, 100% inspection via camera monitoring, and packaging, a two-color pad printing process is integrated into the manufacturing process. A greater challenge during the planning phase was the integration of existing modules from Wirthwein Medical GmbH & Co. KG into the system. Additionally, a handling system had to be developed that can compensate for the dimensional variations of cartons and simultaneously process the inserted PE bags.

Automated Magazine Loading

Another optimization in production is a system for magazine loading of 2 ml bottles, used by the customer in automated laboratory diagnostics. A fully automated solution was also implemented here to meet large demand volumes. The system is designed as a turn-key solution and minimizes material movements. The production personnel responsible for operating the system only need to load empty pallets and remove full ones.

Assembly Systems for Volume Increase

Wirthwein Medical GmbH & Co. KG not only excels in process optimization but also in speed. For example, due to increased batch sizes, another assembly system for so-called "filter tubes," a plastic component needed by the customer for cleaning and preparing DNA samples, was realized within five months. The system fully automates the stamping of three layers of glass fiber fleece and inserts them into the tubes. Subsequently, the bottom of the tube is sealed by thermoforming. The system also features cameras for 100% inspection, a master control system, and fully automatic packaging. Due to the necessary processing of glass fleece in the ISO Class 7 cleanroom, a multi-stage cleaning process using ionized air and a high-performance suction system was implemented to remove particles and dust, preventing contamination.

The Perfect Solution as a Team

"Exclusive investment in expensive automation technology would be shortsighted. It is important to have well-trained personnel who can maintain and operate the systems," explains Dr. Thomas Jakob, Managing Director of Wirthwein Medical GmbH & Co. KG. Therefore, Wirthwein Medical GmbH & Co. KG focuses on comprehensive training for the continuous development of its skilled staff. "I am proud that in-house specialists implement these solutions. Employees are involved in projects from the very beginning. When the human, the machine, and the company's know-how are in harmony, the best solutions for human health are created," says Managing Director Dr. Thomas Jakob.