New Packaging Technologies Ensure Chemical Safety

Robotics and smart systems contribute efficiency to chemical packaging

Preparing chemicals and pharmaceuticals for distribution, transport, storage and use is a demanding operation. Fortunately, modern packaging solutions with advanced technologies and smart systems can increase the efficiency of packaging operations, while also ensuring the safety, efficacy and integrity of complex chemical products.

“When it comes to packaging chemicals and pharmaceuticals, personnel safety is non-negotiable. Additionally, product integrity and compliance with regulations, such as current good manufacturing practices (cGMP), U.S. Food and Drug Administration (FDA) and EU Annex 1 guidelines, must be preserved,” says Katrin Meinikheim, business development coordination manager with Bausch+Stroebel (Ilshofen, Germany; bausch-stroebel.com). “And, waste prevention is critical due to high costs.”

“As sustainability is a growing priority, brand owners are under pressure to reduce material usage, shift to recyclable packaging or offer refillable and reusable solutions without compromising on safety or performance,” adds Markus Urich, director new technologies with Optima Group (Schwaebisch Hall, Germany; optima-packing.com).

“This means demands related to chemical packaging don’t lie in a single area. Rather, they arise from balancing product integrity, operator safety, regulatory compliance, resource efficiency and future sustainability,” explains Urich. “Overcoming these challenges requires a holistic approach that analyzes requirements and risks and defines clear priorities when developing solutions.”

Marvin Krampe, sales head at Beumer Group, (Beckum, Germany; beumergroup.com), continues: “The challenge in chemical packaging processes is improving efficiency while maintaining product integrity. Also, it is essential to reduce costs and minimize waste, particularly the use of consumables. Meeting these goals requires increased automation and the integration of packaging machinery into the processor’s digital infrastructure to streamline operations and support data-driven decision making.”

Role of packaging equipment

While advanced technologies and digitalization have enabled packaging equipment to become more efficient and effective, machinery used to package chemicals must first fulfill several essential requirements, including safety, product integrity and waste reduction.

“Packaging machinery plays an important role in safely preparing chemical products. First, it ensures a safe production environment for personnel. Equally important is the safe and secure packaging of chemical products to ensure stability during transport and safe use by consumers,” notes Urich. “This includes maintaining product integrity through optimized barrier properties and secure opening and closing features that guard against moisture, contamination and temperature fluctuations.

“For example, where product integrity is a key concern, precise dosing technology ensures filling accuracy, whether handling fine powders, dust-forming granulates, viscous pastes or liquids,” explains Urich. “Scalable filling modes can be applied for different container sizes. For sensitive or potentially explosive substances, ATEX-compliant machines are available, along with integrated dust extraction systems and carefully selected contact materials.”

Packaging machines are also essential to product protection, says Ralph Augenstein, director of sales and marketing with Romaco Pharmatechnik GmbH (Karlsruhe, Germany; romaco.com). “Precise automation minimizes product loss during the packaging process by reducing packaging errors to an absolute minimum,” he says. “It also ensures secure packaging. For sensitive products, such as effervescent tablets, packaging machines must pack the products securely, so they are protected from environmental influences.”

Romaco’s HM 1E strip packaging series for effervescent tablets was developed to protect sensitive products from moisture and other environmental influences through unit dose packaging. “What makes this equipment noteworthy is its suitability for integrated manufacturing and packaging processes,” Augenstein says. “In doing so, it supports efficiency, sustainability and safety requirements beyond the machinery itself.”

And high-potency compounds, such as antibody drug conjugates (ADCs) or toxic products, where even minimal contamination can have serious consequences, add another layer of complexity as packaging equipment must operate under strictly controlled, sterile and fully contained conditions.

In these instances, remarks Meinikheim, packaging equipment, such as Baush+Stroebel’s ADC-dedicated fill-finish line (Figure 1), implements end-to-end containment strategies, from pre-inspection and vial transport to aseptic filling and vacuum-free closing, to safeguard both product and process personnel. “A core element of this approach is our pressure-zone concept, which strategically separates cleanroom areas based on contamination risk,” she says. “By creating a dedicated pressure zone between the sorting and filling and stoppering stations, we reduce exposure and maintain aseptic integrity.

“Additionally, this zone separation and pressure-zoning concept allows for the minimization of critical areas, simplifying cleaning, enhancing operator protection and reducing the complexity of validation — while ensuring compliant and efficient processing of high-potency products like ADCs,” she says.

In other cases, materials may not be toxic, but may still have significant challenges, as is the case with pigment packing, according to Thomas Hilling, general manager of the Haver Boecker Institute (Oelde, Germany; haverboecker.com). “Materials like carbon black, titanium dioxide and colored pigments cling to surfaces, causing inefficiencies, spillage and waste during the packaging process,” he says. “Traditional solutions, such as paper valve bags, fall short when protecting these products during transport and storage. That’s where hybrid form-fill-seal (FFS) technology with Haver & Boecker ADAMS technology (Figure 2) stands out. It uses durable, fully sealed bags to shield pigments from inclement weather, contamination and logistical stresses, while also addressing issues such as spillage and clinging materials with advanced dosing mechanisms that ensure accurate material flow and weight control, minimizing spilling and reducing material cling for cleaner and more efficient operations.”

Advanced technologies

In addition to supporting essential requirements, modern packaging machinery combines advanced technologies and smart systems to enable greater packaging efficiency.

“Modern packaging equipment overcomes challenges through advanced technology and smart system integration,” says Beumer’s Krampe. “New technology and development within the weighing process ensures accurate dosing and advanced sealing methods provide a secure sealing process, protecting product integrity and minimizing material waste. Automation and smart integration provide the opportunity to integrate packaging machinery into digital infrastructures, allowing machine control, real-time monitoring, data analysis and process optimization.”

For example, the Beumer fillpac FFS (Figure 3) forms a ready-made polyethylene tubular film into a bag and fills it with chemical products. The system is equipped with an electronic calibration-capable weighing unit, ensuring that the system fills bags with a constant quantity of material within the specified tolerances. Then the system seals the bags with a weight of up to 25 kg. It can process up to 2,600 bags per hour.

The addition of Beumer’s Software Suite with BG Fusion visualization provides operators with a web-enabled user interface for configuration, monitoring and reporting. With this solution, data can be collected and clearly displayed. BG Fusion can be extended through Beumer provided IoT modules. The information collected through the IoT module using data analytics can be analyzed for higher machine reliability and efficiency. Machine data, error messages and information on operation and maintenance are prepared so that users can apply the data for things like predictive maintenance.

And, robotic systems permit greater flexibility in different applications, says Romaco’s Augenstein. “An example of this can be found in our Siebler FlexTrans (Figure 4). It features a flexible transfer unit for strip packaging with up to 900 picks per minute to transfer sealed strips to the cartoner,” he explains. “A camera checks their position and assigns the strips to the robotic vacuum grippers, which then convey the product directly into the cartoner’s bucket chain. The combination of smart functions with the integrative line approach greatly increases efficiency.”

In sterile packaging, especially, robotics are playing a larger role, says Alberto Aleman, director of aftermarket solutions with Steriline North America, Inc. (Bradenton, Fla.; steriline.it). “Because sterile packaging requires eliminating contamination, product loss and operator exposure, robotics, isolators and real-time monitoring systems significantly reduce human intervention, enhance operator safety and ensure consistent product quality. For example, robotic systems minimize vial handling errors, reducing contamination risk while improving repeatability.

“We adopted advanced robotics and integrated vision systems across our filling and packaging lines,” he continues. “These technologies support in-process controls (IPC), like automated fill weight verification or stopper placement inspection, optimizing line efficiency and reducing waste. Integration with SCADA systems allows centralized data management and predictive maintenance, which are becoming crucial in Pharma 4.0 environments” (Figure 5).

He points to Steriline’s Robotic Nesting Filling Line under Isolator as an example. It combines zero-intervention aseptic processing with cutting-edge robotics. This solution ensures maximum sterility, reduces operator risk and complies with Annex 1. “It handles both small and medium batch production with format flexibility, which is particularly valuable for Contract Development and Manufacturing Organizations (CDMOs) and biotech manufacturers working with high-value biologics.”

The addition of machine vision and artificial intelligence (AI) to robotics also allows equipment providers to deliver increasingly innovative machines and lines, says Francesco Stanzani, global commercial director with the Marchesini Group (Pianoro, Italy; marchesini.com). “The use of AI has allowed us to offer increasingly high-performance systems capable of surpassing human inspection capabilities. And AI can be applied not only to product quality inspection systems, but to robotics.

“Among the latest technologies is one created in collaboration with Eyecan. The solution enables robots installed on production lines to become self-learning entities,” continues Stanzani. “Here, AI is used in robotic picking applications, where a camera guides the robotic arms to identify and pick up objects along the packaging line. Thanks to the machine-learning algorithms, Marchesini Group robots can now be programmed using another robot as a tutor. This allow them to autonomously recognize any object in any condition, without the need for a human programmer to write new software. The benefits of this technology include greater flexibility, ease of use and improved overall performance.”

Additionally, today’s integrated process monitoring and smart automation technologies ensure that product quality and compliance are maintained, says Optima’s Urich. “Modern machinery focuses on supporting operability and long-term performance through the use of advanced technologies and smart features, enabling manufacturers to respond to changing market demands while ensuring safe, efficient and compliant packaging processes.”

For example, the Optima Total Care digital platform connects machines via IoT technologies to enable real-time condition monitoring of critical components. “This allows predictive maintenance and helps reduce unplanned downtime. The platform provides transparent dashboards that display key figures such as overall equipment effectiveness, energy consumption and material usage, supporting efficiency improvements and waste reduction. Remote diagnostics and software updates enable quick support without on-site visits,” says Urich.

End-to-end solutions

In addition to the equipment itself, safe and efficient transfer to filling and packaging lines, and specialized product containers are essential components of chemical packaging.

“Material handling conveyors must be designed to transfer materials to the filling/packaging lines,” says Ta’Shanda Rayne, sales engineer with Gericke (Somerset, N.J.; gericke.com). “Integrated turnkey systems capture materials from any point, such as a dryer or bulk-bag unloader, and convey them to a hopper or other vessel to suit specific requirements.”

Rayne points to Gericke’s pneumatic conveyors, which gently and automatically transfer powders and other dry solids from a dryer, mixer or anywhere in the process, directly to the filling or packaging line for loading drums, bags or other containers in precise amounts (Figure 6). “These enclosed conveyors prevent product contamination to safeguard product purity and prevent exposure to the workplace.”

And, combining Gericke’s pneumatic conveyors with their STP-61 intelligent pneumatic conveying automation solution ensures materials are accurately directed into the correct channels. “Our software can be seamlessly integrated with existing facility systems, enabling a smooth transition from conveying to filling,” Rayne says. “For example, operators can manage a drum filling station, remotely filling different aliquots into separate drums from across the facility. This level of control reduces downtime and maximizes operator efficiency and safety by allowing real-time adjustments without interrupting the workflow.”

Double-door transfer systems, such as those from Central Research Laboratories (CRL; Red Wing, Minn.; crlsolutions.com), allow the transfer of hazardous materials into or out of an environment without exposing operators to products, says Isaac Giesen, applications engineering manager with CRL. “Ultimately, the role of equipment used to transfer chemicals to packaging is to keep operators and the environment segregated from hazardous materials,” he says. “Using modern equipment, such as double-door transfer systems, provides a simple means of segregating humans and the environment from what’s inside the canister or bag.

“Traditional methods, such as bagging items, required operators to seal, wrap and tape, which necessitated multiple operators, several layers of protocols and a lot of time,” says Giesen. “Double-door technology removes extra steps and requires just one operator and minutes, versus an hour, while adding safeguards and efficiency.”

Containers also play a role in safely handling chemicals, says Zwoni Denac, product and key account manager for industrial containers with Thielmann (Granada, Spain; thielmann.com). “Thielmann’s high-grade, stainless-steel containers made from AISI 304, 316L, 316Ti.Monel or Duplex, including UN hazardous storage drums, ASME and CE pressure equipment and aseptic options for food and beverage packaging, ensure leak-proof and pressure-resistant storage, regulatory compliance, protection from contamination and environmental exposure and safe handling for operators with safe filling and emptying systems and high resistance against fire.

“Our double-walled systems with an intermediate layer are designed to absorb hazardous substances in case of leakage,” continues Denac. “These technologies ensure long-lasting durability, minimize the risk of accidents and contribute to environmental protection. By offering alternatives to plastic, we are developing safer and more sustainable solutions.”

He adds that containers are also going high tech. “Smart technologies are being integrated to monitor pressure, temperature and location of liquids in real time, improving safety and traceability,” says Denac. “Additionally, user-friendly systems are being developed to simplify filling and emptying processes.”