Automating saline bag production for increased efficiency
A leading pharmaceutical company in Lille, France, needed a way to automate the production of saline solution bags. Their factory relied on manual labour for cutting, filling, and labeling the bags, but they wanted to automate 50% of production to improve efficiency while maintaining a manual backup system for supply security.
The automated system was nearly complete, capable of manufacturing, filling, sealing, and boxing the bags. However, one critical issue remained, printing batch codes onto the 1.5m-wide plastic reels. Existing industrial thermal printers were too narrow, creating a major bottleneck in the automation process.
We worked closely with the client to design a completely new approach. Instead of moving a print head across the plastic, we reimagined the process, keeping the print head fixed while moving the entire printer across the reel.
This innovative solution allowed seamless printing across any width of material. To further improve efficiency, we engineered a bidirectional printing function where the reel shifted slightly after each pass, allowing the printer to continue printing in the opposite direction.
Custom printing solution for wide format packaging
What did this project involve?
- Design of Stepper motor control and printing PCB’s
- Design of 19” Control Rack
- PCB Assembly
- CPLD Logic design
- Embedded Firmware
- CNC panel machining and engraving
- Factory Installation and commissioning
Engineering a high precision industrial printing system
Mechanical engineering
to design a system that could transport the printer smoothly without losing accuracy.
Motor and gearbox integration
to enable precise and controlled movement.
Electronic development
using FPGA clock controllers to synchronise printing with reel movement.
Software programming
to automate the process and ensure seamless operation.
On-site installation and testing
to integrate the system into the existing production line
Deploying an industry first in pharmaceutical manufacturing
The prototype worked so well that instead of proceeding with a full-scale production model, the client installed it directly into their French factory. Winter and Smith supported the on-site commissioning, fine-tuning the system for real-world production.
The cross web printer’s success led to further orders for large-scale printing applications beyond saline bag manufacturing, proving its versatility in industrial packaging.
Transforming industrial printing with innovation and engineering
By challenging traditional printing methods and engineering a completely custom solution, Winter and Smith helped revolutionise pharmaceutical packaging. The cross web printer eliminated a key bottleneck in automation, proving that innovative thinking and precision engineering can solve even the most complex manufacturing challenges.
