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Pfizer Enhances Capsule Filling/Weighing in Freiburg, Germany

For more than 30 years, Pfizer’s Freiburg facility has used Bosch machinery that has produced benefits such as lean manufacturing, sustainability and reduced waste. It’s no wonder more equipment will be added in 2017.

Capsule filling operations in Freiburg, Germany are performed automatically on three building levels.
Capsule filling operations in Freiburg, Germany are performed automatically on three building levels.

Pfizer Manufacturing GmbH’s site in Freiburg, Germany specializes in solid pharmaceutical production, including cholesterol-lowering agents and drugs for the treatment of cardiovascular diseases or epilepsy. The facility relies on lean processes and robust machinery.

For example, capsules are filled and weighed on three levels at the site, with minimal operator intervention, using several GKF capsule filling machines and KKE capsule checkweighers from Bosch Packaging Technology. To be clear, the GKF equipment does not fill capsules into blisters or other package types.

Every year, the Freiburg pharmaceutical factory produces six billion tablets and capsules, and more than 200 million packages, in more than 3,000 layouts for the global market. To achieve these high quantities, all production and transportation processes are highly automated.

The site, which employs 950 people, has built a reputation for environmental protection and sustainability. And beyond the Pfizer group, the plant is recognized for its lean manufacturing. “5-S-Best in Class”—Pfizer is reported as the first pharmaceutical producer to be awarded the quality seal from the international Kaizen institute for standardized, lean work processes.

Fully automated on three levels

Capsule filling operations at the Freiburg site are performed automatically on three building levels. The second floor accommodates the powder containers and empty capsules. Here, the base material is conveyed in containers via remote-controlled automated guided vehicles (AGVs). The powder is directed downward through the floor straight into the capsule filling machine situated on the first floor, where it is processed into filled capsules. On the bottom or ground floor, a container collects the weighed capsules, which are then transferred to the subsequent packaging process.

“There is one operator working on the first floor,” explains Eric Fisch, Pfizer Freiburg Production Engineer. “The two other floors are frequented by specialist personnel for cleaning and maintenance.”

The capsule filling machines also set standards in terms of energy efficiency. “Right from the beginning, we planned the factory so that the powder flow can take place without energy input,” says Fisch. “And the concept has stood the test until this very day.”

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