Hybrid Transport Architecture for Pharmaceutical Packaging Lines

Application Area: Primary and Secondary Packaging
Industry Sector: Pharmaceutical and Nutraceutical Packaging Machinery

Körber develops processing and packaging equipment for the international pharmaceutical and nutraceutical sectors, handling unit-dose products such as granulates, powders, liquids, and pastes. In pharmaceutical packaging lines, product diversity, frequent recipe changes, and shifting stick-pack dimensions present significant operational bottlenecks. Conventional mechanical transport systems with fixed linked pitches restrict adaptability, require extensive dedicated format change parts, and extend line changeover downtime during recipe transitions.

Addressing Format Constraints with Hybrid Kinematics
To overcome fixed-geometry limitations, Körber developed the SPE6-P2 stick pack line, which integrates primary forming-filling-sealing and secondary cartoning into a single compact footprint. Rather than using an entirely mechanical drive chain or relying exclusively on magnetic levitation throughout the entire circuit, the machine incorporates a hybrid transport methodology. The engineering team integrated B&R ACOPOStrak intelligent track segments alongside Körber proprietary mechanical conveyance, managing both through a unified automation platform.

Intelligent Shuttle Control and Unified Automation
Within this architecture, seven ACOPOStrak segments manage targeted motion tasks where independent shuttle positioning and dynamic pitch synchronization are critical. In parallel, Körber mechanical drive modules handle non-critical intermediate transport and shuttle returns, optimizing hardware expenses. Stick-pack transfer into the integrated cartoner is performed by a gantry kinematics unit controlled via B&R ACOPOSmotor drives and the X20 control platform.

Ulf Leineke, Vice President Design Machinery at Körber, noted that conventional track systems are limited by fixed geometries, whereas using ACOPOStrak specifically where positioning accuracy is required reduces system complexity, cuts investment costs, and provides freedom in machine layout.




Throughput Gains and Tool-Free Changeover Operations
The resulting hybrid machine operates at speeds up to 600 stick packs per minute across varying film and pouch dimensions. System adjustments occur primarily via software-defined profile modifications rather than mechanical format swaps, shortening batch transition times and eliminating mechanical wear components. Combining targeted linear motor segments with standard conveyance reduced total machine footprint and initial capital cost while maintaining required positioning precision across primary and secondary packaging workflows.

Leineke explained that the openness of the control platform provided the freedom to combine internal transport concepts with linear track technology, multi-axis motion control, and cartoning robotics into one architecture. Unified software control allows operators to commission, monitor, and diagnose all transport modules through a centralized interface.



Edited by Romila DSilva, Induportals Editor, with AI assistance.