VarioFill: Rotzinger sets new standards with highly flexible filling and capping platform for OTC products

With the highly flexible VarioFill filling and capping platform, Rotzinger PharmaPack halves the footprint thanks to interchangeable modules and a high degree of automation.

With VarioFill, the use of pucks and other guiding form parts is eliminated, making transportation particularly gentle.

– Highest flexibility in products, containers, and closure types
– Halved footprint thanks to exchangeable modules and high degree of automation
– Same machine base, easy format changes, and gentle transport

Rotzinger PharmaPack introduces a new filling and sealing platform for over-the-counter (OTC) products such as non-aseptic pharmaceuticals as well as solid and liquid products from the cosmetics, personal care, and dietary supplement sectors. VarioFill combines the advantages of formerly long lines into a compact and modular platform: “Where manufacturers and contract packers previously needed new machines for different products and closures, they can now process everything on one platform with VarioFill: from non-aseptic pharmaceutical liquids like eye drops and cough syrup to cosmetics such as creams and facial serums, to solid forms like tablets and capsules. Additionally, there are various packaging materials and shapes, as well as different closure types — all in highly variable output quantities,” explains Michael Gensheimer, Product Manager at Rotzinger PharmaPack.

Over 50 percent space savings through modular design

One of the many advantages of the VarioFill platform is its small footprint. “In fact, VarioFill is currently the most space-saving solution of its kind on the market,” emphasizes Gensheimer. Thanks to a high degree of automation and exchangeable modules, space savings exceed 50 percent. “Modularity in VarioFill is much more than just a buzzword. It is a lived reality.” This is especially beneficial during frequent product changes: The identical machine base across all variants allows for the installation of new stations and modules. “A reconfiguration of the platform with the appropriate modules is sufficient — and the line is ready for new requirements at low investment costs,” the product manager highlights.

Gentle transport and 100 percent IPK

Before filling, containers are fed into the transport system. Depending on the needs, different solutions can be integrated and combined. The feeding of stationary objects such as glass bottles is carried out via a conveyor system, while Rotzinger’s developed pickFeeder sorts plastic bottles and transfers them using delta robots. Since the magnetically driven universal grippers can adapt to almost all shapes, the use of pucks and other guiding format parts is eliminated, making transport particularly gentle.

After the cleaning station, containers are weighed empty using 100 percent in-process control (IPK). After filling, which is performed with sealless rotary piston pumps or tablet and capsule cappers, another IPK is conducted. On several, freely configurable closure stations, containers are variably fitted with push-on, screw, pump, or crimp closures. A Cleaning-in-Place (CIP) system ensures fully automatic cleaning of the product-contacting parts in the filling area by automatically moving them to the cleaning position, thoroughly cleaning them, and then returning them to the production position.

First customers already convinced

The very positive customer feedback shows that Rotzinger PharmaPack, with this innovative solution, meets the needs of manufacturers and contract packers across all relevant industries: “The response from the pharmaceutical, cosmetics, and dietary supplement industries is great. Even before the official market launch, we sold two VarioFill lines; the first is already in production at a customer — and more will follow,” Gensheimer is pleased to say. Customers are particularly impressed by the modular design. “This demonstrates that we have successfully implemented our motto ‘Configure instead of construct.’ Just as the VarioFill platform is designed to be modular from the ground up, our customers can assemble their solutions tailored to their production requirements — and change or expand them at any time with flexibility,” Gensheimer summarizes.