Case Study: Allergan / eye drops


Allergan USA presented the Schubert-Pharma specialists with an extremely unusual mandate. A vial product with light-sensitive eye fluid had to be hermetically packaged in a plastic tray. Also, another, non-prescription vial product had to be packaged in a folding cardboard box in which the product would then be displayed on shelf.

 The products would be made available offline in cartridges and had to be packaged with an output of up to 500 products per minute in nine formats. The unique challenge was that both products had to be handled on the same packaging line.

Following an intensive project planning phase, the Schubert Packaging Systems project engineers presented a perfectly cohesive system concept and were awarded the contract to implement this highly extensive packaging line. As a general contractor and contract partner to Allergan, Schubert Pharma was responsible for the selection of “best-fit” suppliers.

Ultimately, ten partner companies brought the packaging system to life. The contract included a complete risk-based validation package, as well as the integration of all system components in Crailsheim. Following extensive qualification work, plant approval runs and training of customer staff, the system was delivered to the customer and put into operation within just a few weeks.

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BFS Products

Case Study: Altana (now Takeda)


A well know bottler of ampoules and vials packages its products on Schubert-Pharma systems. The system is a blister and top-load line with an output of up to 300 ampoules per minute. The Schubert-Pharma line, engineered for Takeda, is characterized by the decoupling of the thermoforming machine from the filling and cartoning process.

The packaging line is capable of packaging both vials (standing in a tray) and ampoules (lying in a clip tray). Especially the large range of formats of this application is noteworthy. For example, small packages of 5 vials or ampoules packed in a blister pack per carton can be packaged as well as 10 blisters with 5 products per carton.

This packaging solution for up to 300 products per minute consists of the following steps and functions:

  • Shaping the blisters
  • Stamping the blisters
  • Prepare the blisters for product loading
  • Product feeding and grouping
  • Loading the blisters with vials or ampoules
  • Erecting the top-load cartons
  • Loading the individual cartons
  • Adding the information leaflet
  • Closing the cartons
  • Coding the individual cartons with ink printers
  • Forwarding the packages to downstream transport logistics

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