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400 square meters of automatic warehouse "home" for 100 million capsules

Release Time: 2018-12-18 10:44:00.000

Based on the concept of Industry 4.0 , Wealth Depot is a fully automated warehouse upgraded and transformed for capsules in Suzhou.

It solves the storage problem of an annual output of 48 billion empty capsules, and realizes the automation of the entire process of storage operations, greatly improving logistics efficiency.


What can 400 square meters of space do? A luxury villa is basically sufficient; an office that can accommodate up to 100 people is OK; a restaurant with 42 tables for four is just right. However, have you ever thought that a space of 400 square meters can also be used as a drug warehouse for storing more than 100 million capsules?

In 2017, Suzhou Capsule Co., Ltd., the largest manufacturer of empty capsules in China, joined forces with Wealth Depot, a company specializing in providing intelligent logistics solutions, to successfully build a fully automated warehouse, integrating digital production packaging and intelligent storage functions. as a key component of its Industry 4.0 production plant.

400 square meters of automatic warehouse "home" for 100 million capsules

Appearance of Suzhou Capsule Factory

Fully automatic warehouse: overall design, precise control

Suzhou Capsule Co., Ltd. is one of the top ten production bases of CAPSUGEL in the world, with an annual output of 48 billion empty capsules. It adopts fully automated control operations, strict indoor cleaning procedures and quality monitoring, and air temperature and humidity flow control centers. Leading production technology and conditions to ensure quality products. The newly built automatic warehouse is closely connected with the production line, shouldering the functions of finished product storage and delivery, which greatly improves the logistics efficiency and saves manpower.

From line feeding, weighing, labeling, box sealing, metal detection, warehousing, to the final delivery of ordered products, the overall warehousing operation process has been fully automated, and at the same time, every inch of space in the warehouse has been fully utilized. System designer Danny revealed that the whole project integrates equipment from more than a dozen different manufacturers. Different devices need to complement each other in order to achieve efficient operation of the entire automation system. This means that designers must not only accurately control the overall logistics system, but also have a good understanding of the characteristics of each device.

Another design feature worth mentioning is the corridor between the packing area (clean room) and the storage shipping area. Before the transformation, 9 to 12 people were needed to move the sealed medicines to the storage and delivery area, and a pedestrian passage was needed between the two areas. This is unsatisfactory in terms of cost, efficiency and safety. For this reason, Wealth Depot designed a fully sealed and pollution-free corridor at a position 4.2 meters above the ground. The cartons sealed in the packaging area are taken to a high place by the elevator, enter the corridor, and finally arrive at the Miniload intensive storage area.

400 square meters of automatic warehouse "home" for 100 million capsules

Miniload library

400 square meters of automatic warehouse "home" for 100 million capsules

Finished products enter the logistics system from the production workshop

400 square meters of automatic warehouse "home" for 100 million capsules

The elevator sends the finished product from the workshop to the Miniload warehouse

In the link of goods out of the warehouse, in order to avoid the pollution of the traditional chain pallet conveyor line to the pallets and cartons, Wealth Depot specially customized a synchronous belt pallet conveyor line for Suzhou Capsule. This design greatly reduces the possible contamination of drugs during the outbound process, and at the same time fully reflects the high level of system detail design capabilities of the large library.

400 square meters of automatic warehouse "home" for 100 million capsules

Synchronous belt transfer design to avoid oil pollution

 

In addition, during the system design process, Wealth Depot strictly follows the requirements of GMP, and always puts drug safety in the first place. The logistics system not only guarantees the quality of Suzhou capsule products, but also guarantees the safety of consumers.

Main work flow

After the cartons filled with capsules come off the production line and enter the logistics system of the warehouse, they need to go through double monitoring before they can be put into the warehouse. The first is weighing monitoring. If the standard weight is not reached, the medicine will be rejected for inspection. Immediately afterwards, the carton enters the specially customized A4 paper printing and labeling station, and the machine automatically prints and pastes the paper label.

400 square meters of automatic warehouse "home" for 100 million capsules

A4 paper label printing and labeling

After labeling, the box is automatically sealed with different adhesive tapes according to different capsule types. Once complete, the boxes are metal-monitored to ensure the medicines are free of any impurities. Drugs that pass these two monitorings can be stored in the warehouse.

400 square meters of automatic warehouse "home" for 100 million capsules

Automatic sealing

When shipping, Miniload sends out the finished product boxes required by the delivery batch, and the tailor-made ABB manipulator automatically codes pallets with different patterns according to the total number of boxes in the delivery batch .

400 square meters of automatic warehouse "home" for 100 million capsules

Robot automatic palletizing

The empty pallets required by the code disc are provided by the automatic code disc and the unloading manipulator. The stacked pallets are sent to the delivery buffer area and wait for the arrival of the truck.

400 square meters of automatic warehouse "home" for 100 million capsules

Empty pallet returns

Customized services solve industry application pain points

In order to obtain the best results, advanced equipment is essential in a maximally optimized logistics system integration solution. In response to the huge production volume of capsules in Suzhou, Wealth Depot and TGW worked closely together to customize the first four-extension Miniload stacker in China, which can carry four boxes of goods at a time, greatly speeding up the storage and retrieval of goods (400 in and out of the warehouse per hour) multiple boxes) to shorten the delivery and loading time. At the same time, Wealth Depot also adopted ABB manipulators with excellent flexibility, which greatly improved the accuracy of goods grabbing and improved the overall operating efficiency of goods from sorting to delivery.

400 square meters of automatic warehouse "home" for 100 million capsules

Miniload library and four-extension Miniload stacker

 

Suzhou Capsule Company has been in operation for 30 years and adopts the mode of continuous production and centralized delivery, so it needs a lot of space for temporary storage of deliveries.

400 square meters of automatic warehouse "home" for 100 million capsules

Shipping Cache

 

As business volumes continue to increase, factory space is at a premium. After the implementation of the project, the overall process has been fully automated from line feeding, weighing, labeling, sealing, metal detection, storage, code plate, to the final order product delivery, saving a lot of manpower and space. It reduces the pollution that may be caused by manual contact with products, and greatly improves the level of logistics management and operational efficiency.



 

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