Challenge
A pharmaceutical customer needed a high throughput automated system to open non-standard cardboard packaging, extract multiple dosing pens from each pack, and sort them into trays without any cosmetic or functional damage.
Each pack contained several pens with irregular geometry, variable centres of mass and spring-loaded ends, all of which made handling unpredictable. Traditional cutting systems risked damaging the pens or creating excessive dust, while vibratory or gravity-based sorting methods could not reliably orient the pens due to their inconsistent rolling behaviour.
The system also had to process several packs simultaneously to achieve the required cycle time, maintain extremely clean operating conditions, and run continuously with minimal human involvement. Handling integrity was critical. Even small scratches or marks on the pens would cause them to be rejected downstream.
In short: engineer a gentle, predictable and contamination-aware automation process for products that do not behave predictably.
How Amtek Tackled It
We began by studying the packaging materials, the folding and tearing behaviour of the cardboard, and the dynamic characteristics of the pens themselves. Early concepts were tested using rapid 3D-printed prototypes to evaluate how the pens moved, bounced, rotated and interacted with guiding surfaces.
Developing a clean, controlled packaging-opening mechanism Opening the packs without generating dust or damaging the pens required an extensive exploration of cutting and peeling techniques. We trialled:
- Double-sided blades mounted within a guided linear pneumatic actuator to achieve consistent cuts in both directions, extending blade life and maintaining alignment.
• A radial spring return mechanism that re-centred the blade automatically between cycles, reducing repositioning time and component wear.
• Pneumatic gripping and peeling concepts where lids were lifted without any cutting, assessed for cleanliness and suitability for high speed operation.
Each concept was evaluated not only for precision but also for dust generation, repeatability and long-term durability. A dedicated waste collection path was incorporated so that all offcuts and opened packaging were channeled into a receptacle positioned for safe operator access during routine emptying. Because pens had inconsistent mass distribution and rolling behaviour, conventional feeders were ineffective. We developed a controlled sorting mechanism using a helical track that Allowed it to drop into trays in a repeatable and predictable orientation. 3D printed variants were tested to optimise friction, curvature, spacing and tolerances. The final design delivered stable, gentle handling while maintaining throughput targets.
Integrating high-speed robotics and continuous operation, the final system combined:
- Linear pneumatic actuation for cutting and opening
• Robotic pick and place motion for handling multiple packs simultaneously
• Buffering zones to keep operations continuous
• A sorting and orientation mechanism for the pens
Throughout development the focus was on protecting the pens, minimising impact forces, maintaining clean handling, and ensuring the system could run reliably for long periods without interruption.
The Solution and Its Impact
Amtek delivered a fully automated packaging opening and sorting system capable of handling delicate dosing pens cleanly, safely and consistently at the customer’s required throughput.
Reliable, gentle product handling Pens were removed without scratches, surface marks or impact forces that could compromise quality.
A low-dust, contamination-aware process The controlled cutting mechanism, sealed extraction path and integrated waste collection reduced airborne fibres and maintained a cleaner environment.
Consistent high-throughput performance Processing multiple packs at once, supported by pneumatic actuation and automatic blade recentering, enabled long continuous production runs with minimal downtime.
Accurate and repeatable pen orientation The sorting mechanism ensured every pen entered trays in the correct orientation, reducing downstream manual correction.
A validated, robust and scalable automation solution AIterative prototyping and testing ensured high reliability and allowed the system to be adapted for future packaging or pen variants.
Trust Amtek to deliver high-quality and reliable engineering solutions that drive innovation.
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