Packaging of injection-moulded plastic parts
PHARMACEUTICAL & HEALTHCARE
PACKAGING
Context & Challenges
A major player in medical plastics processing, specialised in the manufacturing of plastic pharmaceutical devices (injection moulding, assembly and packaging), was looking for a high-performance sealing solution for the packaging of injection-moulded plastic parts.
In a highly regulated pharmaceutical environment, the challenge was to secure sealing operations while maintaining high productivity, consistent seal quality and full process traceability, all under cleanroom conditions.
Objectives
- Ensure seal integrity and compliance in line with GMP requirements
- Optimise throughput and productivity at the sealing station
- Significantly reduce rejects and sealing defects
- Improve operator ergonomics in a repetitive production environment
Ensure full regulatory compliance with complete process validation (FAT, SAT, IQ, OQ) and end-to-end traceability
Technical Solutions
Installed equipment
- Sealing technology: regulated impulse sealing (Impulse Driver), ensuring precise control of sealing parameters
- Seal type: 10 mm double band seal, providing enhanced leak tightness
- Sealing cycle: pneumatic closing, ensuring excellent repeatability and consistency
Quality Control & Traceability
- Integrated sealing temperature control via dual OPTRIS sensors
- Secure control interface with four access levels: Operator, Maintenance, Supervisor and Administrator
- Full traceability of parameters, compliant with pharmaceutical requirements and quality audits
Ergonomics & Cleanroom Compatibility
- Design using cleanroom-compatible materials
- Easy access for cleaning, maintenance and adjustments
Adjustable bag support table with pneumatic cylinder, improving ergonomics and reducing operator strain
Packaging dimensions to be sealed :
700 x 900mm
Product packaged : injection-moulded plastic parts
Seal width : two 10 mm bands
Packaging material : polyethylene
Key Features
- Bag type: polyethylene
- Dimensions: 700 × 900 mm
- Packaged products: injection-moulded plastic parts for pharmaceutical applications
- Major constraints:
- Strict regulatory standards
- Sealing parameter security and traceability
- Cleanroom compatibility
The Bernhardt solution enabled the customer to:
- Secure and stabilise sealing operations in a GMP environment
- Reduce defects and rejects, improving overall production quality
- Increase productivity through optimised sealing throughput
- Strengthen traceability and regulatory compliance
- Improve operator comfort and ergonomics at the packaging workstation
This project illustrates Bernhardt’s ability to deliver tailor-made sealing solutions that meet the stringent requirements of the pharmaceutical and medical device sectors.
Proof in pictures
