Assembly of drug delivery systems

For the assembly of drug delivery systems we offer you both modern, fully automatic assembly technologies and semi-automatic or manual assembly, which are primarily more affordable for smaller series. At Gerresheimer you will thus find a cost-optimal assembly solution for any product.

Especially for large series production of drug delivery systems, automation coordinated precisely with the product, project and processes has a decisive influence on the quality and economic efficiency of production. The technicians, mechanics, electricians, designers and programmers of the Automation department are responsible for these tasks at our Technical Competence Center (TCC) in Wackersdorf (Germany). The 45-member team specifies, procures, qualifies, designs and builds systems for special machinery, automatic testing systems and loading and unloading handling, which are used at all of our production facilities in Europe, the USA, and Asia.

We conceive of and build assembly systems for the highly precise delivery and assembly of plastic and metal parts at the highest possible speed. Intelligent solutions for the delivery and separation of plastic and metal parts ensure damage-free, precisely positioned insertion of the parts to be assembled. Following removal, we suction out the receptacles in order to ensure clean assembly of each individual assembly unit.

Our assembly lines ensure the optimal surface quality of the products through assembly that is gentle with the visible surfaces and visual inspection for damage to the visual parts within the assembly system. A 100% in-process inspection of the assembly steps, the parameters critical for quality and the module and product functions takes place with a large number of intelligent camera systems and inspection stations in the assembly system. Gap-free documentation of the assembly processes ensures the traceability of all batches.

We assume responsibility not only for the assembly of plastic and metal parts, but also install the electronics necessary for the end device. In the case of inhalers, for example, we install the electronic counters for dosing, atomization actuators and the most varied sensors. We integrate punch contacts and install circuit boards, which are then, for example, designed as switches. For the assembly of electronics, we create our own clean rooms, which are also equipped with a special ESD protective floor for preventing static charge. Special camera tests in the assembly system ensure the correctly positioned insertion of circuit boards, the damage-free positioning and snap-fitting of punch parts and the correct position of switches. A gap-free in-line function test at the assembly system rounds off our range of services.

Particularly in the case of drug delivery systems and pharmaceutical packaging, the highest requirements for quality apply, which is also reflected in the effort required for the assembly of the systems. We offer the cleanliness and quality requirements of the respective product in correspondence with all assembly steps in the clean room according to ISO 14644-1 ISO class 7, 8, 9 and GMP classes C and D.

Integration of Active Ingredient and Drug Delivery Device

As an internationally active full-service provider, Gerresheimer covers the entire value chain for the pharmaceutical and healthcare industries. Our holistic approach extends from the initial idea through development and industrialization to high-precision series production. We seamlessly integrate downstream processes such as packaging, serialization, and distribution into an efficient, end-to-end workflow.

Pharmaceutical assembly plays a central strategic role in this offering. As a decisive link, this process combines the drug delivery device with the pre-filled drug to create a market-ready combination product. Through this vertical integration, customers benefit from significantly reduced lead times and a substantial reduction in supply chain complexity. Simultaneously, we guarantee maximum process efficiency without compromising product safety.

The technical implementation includes the precise mechanical assembly of sensitive components—such as the insertion of plunger rods or pre-filled cartridges—complemented by extensive functional testing. By utilizing validated force tests as well as activation and release testing, we ensure the reliable functionality of every single unit. All processes at Gerresheimer are subject to strict GMP guidelines and specific regulatory requirements for medical devices. Seamless documentation and rigorous control of all processes ensure full compliance with international authorities at all times, upholding the highest quality standards for patients and users worldwide.

In this article, learn more about our long-standing expertise and discover practical examples of pharmaceutical assembly.

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