Injection molding plastic parts and assembly units in the cleanroom
Manufacturing

Worldwide production and cleanroom capacity

Seven days a week, day and night: We are producing medical plastic systems with millions of parts nonstop with fully automated production and assembly facilities worldwide - always quick, cost-efficient and with consistently high quality. Prior to the start of production, the setup of the systems is simulated in order to set up the sequence of individual production steps economically and efficiently – short routes for production are the goal.

Your PLUS with Gerresheimer

Full Service: From injection molding to the ready-for-sale product

Injection molding and assembly of an inhaler in the clean room
Injection molded parts and metal parts of an inhaler

The full service of Gerresheimer Medical Systems encompasses much more than 100% quality injection molding. It includes many different post-production processing methods – from completion and assembly of modules to optical, haptic and functional finishing through to filling, sealing and packaging of ready-to-use systems. We even take care of the procurement of high-quality external parts and assume responsibility for the surface decoration.

40 years of experience in clean room production

Injection molding of plastic parts and plastic assembly units in clean room in Germany
Injection molding of plastic parts and plastic modules in the clean room according to ISO 14644-1 ISO class 8 in Pfreimd, Germany

The production of high quality drug delivery systems, medical and diagnostics products requires an adequate production environment. With nearly 40 years of experience in clean room production according to ISO 14644-1 ISO classes 7, 8 and 9, and coverage of the entire value creation chain in the clean room, we are your specialist for clean room production.

Cleanliness along the value creation chain

Injection mold clean room plastic assembly units Germany
Injection molding, assembly and testing of an inhaler in the clean room according to ISO 14644-1 ISO class 8 in Horšovský Týn, Czech Republic

In order to fulfill the strictest requirements for cleanliness, we don't interrupt the cleanliness chain during production. The entire value creation chain, from precision injection molding in large and small series production through product refinement, fully automatic, semi-automatic and manual assembly of plastic parts, assembly units and metal parts extending to the testing and packaging takes place in the clean room according to ISO 14644-1 ISO classes 7, 8 and 9. We develop production concepts specific to the product that are specially tailored to the quality claims of the pharmaceuticals and medical technology branches. For example, for the production of an inhaler we have created a room-in-room concept with which we avoid the occurrence of particles caused by moving parts like feed pipes by way of an encapsulated injection molding machine.

Worldwide production and clean room capacities

Injection molding clean room plastic assembly units China
Injection molding production of plastic parts and assembly units in the clean room according to ISO 14644-1 ISO class 8 in Dongguan City, China

As a global player we think and act international. Therefore, we offer our customers 100,000 sqm of production area, of this around 50,000 sqm of clean room area in accordance with ISO 14644-1 ISO classes 7, 8 and 9 in Germany (Pfreimd and Bünde), Switzerland (Küssnacht), the Czech Republic (Horšovský Týn), the USA (Peachtree City, near Atlanta), Brazil (Indaiatuba, near São Paulo) and China (Dongguan City, near Hong Kong).

We meet with our customers "on location"

Injection molding clean room plastic assembly units Brazil
Injection molding of an insulin pen in the clean room according to ISO 14644-1 ISO class 9 in Indaiatuba, Brazil

We of course meet with our customers "on location". For example, we have set up a complete production facility for a leading pharmaceuticals company in the diabetes field in Indaiatuba (Brazil). Plastic parts and assembly units for insulin pens are produced there in the clean room according to ISO 14644-1 ISO class 9 and then delivered to the nearby production facility of the customer. Final assembly and the filling of the cartridge with the active ingredient then takes place here. With Gerresheimer Medical Systems, you decide in favor of a flexible company with short decision paths that focuses on the wishes of customers in its thought and actions.

Fully automated large series production and semi-automatic small-series production

Micro-injection molding of plastic parts
Micro injection molding: Component for an inhaler: ø 5.21 mm, height 1.56 mm

Our core competence is in fully automatic large series production and in the manual and semi-automatic small series production of complex and technically sophisticated systems consisting of many individual plastic and purchased parts. The combination of plastic and metal for cannulas for implants, for needles for lancets and lancet magazines, or for springs for drive elements of inhalers are just as much part of our know-how as the production of the smallest parts in high-cavity injection molds.

Procurement of purchased parts and electronics

Assembly of electronics and plastic in the clean room
Fully automatic insertion of a spring into an auto-injector in the clean room according to ISO 14644-1 ISO class 8 in Küssnacht, Switzerland

Extending beyond injection molding, we also procure the required purchased parts and, as an expert for the combination of plastic and metal, also assume responsibility for the purchasing of all electronics for end devices upon request. For example, we can acquire electronic counters for inhalers for the dosing, atomization actuators and the most varied sensors. We purchase RFID chips for tracing with disposable items in the lab, punch contacts and circuit boards, which are then constructed as switches, for example. Our international purchasing team procures springs for drive elements, cannulas for implants and needles for lancing devices. In the process we make use of strategic partners who are subject to regular quality audits and fulfill our strict requirements without exception.

Uniform manufacturing execution system

Production control of injection molding and assembly
Monitoring and control of production with the internationally uniform Management Execution System (MES)

Top performances in production are no longer possible today without high performance data processing. We therefore control and monitor production throughout the company with an internationally uniform Management Execution System (MES). Automated quality tests coupled with the production process and completely documented traceability ensure that all products correspond to the required quality standard.

Contact
Contact us!
Alexander Schiessl
Sales Europe
Phone
+49 9431 639 6292
Shane Anderson
Sales North America
Phone
+1 609 369 1679
Rafael Kollofrath
Sales South America
Phone
+49 9431 639 6162
Mike Nie
Sales Asia
Phone
+86 769 8851 7100 317