Fully automatic assembly unit for an inhaler in the clean room in Germany

Optimal assembly solutions for any product

When assembling complex systems, we select the optimal assembly solution for our customers specific to the product. We assembly plastic parts, metal parts and electronics precisely and quickly. In order to ensure customer requirements for the highest surface quality and 100% functional safety, we integrate a variety of intelligent camera systems and inspection stations into the assembly system.

Your PLUS with Gerresheimer

Fully automatic, semi-automatic and manual assembly

Clean room assembly of an inhaler in China
Manual assembly of an inhaler in the clean room according to ISO 14644-1 ISO class 8 in Dongguan City, China

For the assembly of plastic parts, assembly units and complete devices 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. For decades now we have supplied our customers from the pharmaceuticals and medical technology industries with countless assembly units and systems, designed thousands of product-specific assembly processes and reliably carried out billions of assembly procedures. For example, we assemble more than 100 million inhalers every year.

Own automation engineering department

Automatic assembly system in the clean room class 8 for an inhaler
Automatic assembly system for an inhaler in the clean room according to ISO 14644-1 ISO class 8 in Horšovský Týn, Czech Republic

Especially for large series production, 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.

Precise and quick feeding of plastic and metal parts

Highly automated assembly of plastic parts in the clean room
Vibratory feeder for the feeding of plastic parts

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.

Best surface quality and functional security

Injection mold, assembly, visual inspection
Visual inspection of an inhaler component for damage

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.

Assembly of electronics

Clean room production inhalers injection mold assembly electronics
Assembly of electronics into an inhaler

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. Gerresheimer Medical Systems also assumes responsibility for the assembly of RFID chips, because the traceability of tests and the providing of information for the
analysis device by way of the test to be carried out are continuously increasing in importance. 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.

Assembly in the clean room

Fully automatic assembly of an inhaler in the clean room
Fully automatic assembly of an inhaler in the clean room according to ISO 14644-1 ISO class 8 in Pfreimd, Germany

Particularly in the case of drug delivery systems, medical and medical technology devices, 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 8 and 9.

Contact us!
Martin Pütz
Sales Europe
+49 9431 639 6971
Aron Haber
Sales North America
+1 770 688 5000
Rafael Kollofrath
Sales South America
+49 9431 639 6162
Mike Nie
Sales Asia
+86 769 8851 7100 317