Fully automated pipette tip production in the clean room

We automated pipette tip production in the cleanroom with a compact, easy-to-operate system. The sophisticated system concept enabled an impressively high overall equipment effectiveness (OEE).   

The challenge   

The manufacture of pipette tips places the highest demands on production. Especially with such demanding specifications: 96 pipette tips had to be transferred, assembled, inspected and packed within a few seconds. In addition to the very tight measurement tolerances for the pipette tips, the overall traceability down to the individual tip was a major challenge. The system also had to be designed in such a way that it was as easy to operate as possible and required minimal maintenance and cleaning. All with the aim of achieving the highest possible overall equipment effectiveness (OEE). 

The solution   

For the production line, we combined seven Stäubli Scara robots and three Acopostrack transport systems with state-of-the-art image processing systems and laser scanners. The system is operated in a GMP C cleanroom. At the customer's request, we configured the system so that if needed the parts are fed and removed by the operator. Normally this runs fully automatically from an injection moulding machine.   

The system processes two different types of pipette tips simultaneously, which are then packed together in a rack. The pipette tips are placed on magnetic shuttles by a suction gripper from the conveyor belt. These receive the information as to which cavity is in which position and pass through the following stations:  

• Bottom view control Pipette tips  
• Filter assembly  
• Top-view check of the filter position  
• Removal of bad parts  
• Filling up good parts  
• Transfer to the sales rack.  

Finally, the sales rack is labeled, checked for completeness and transported out of the system via a conveyor belt. A packaging system could also be added directly here.  

The central graphical user interface via a 24-inch touchscreen enables intuitive operation of the system. Clear user guidelines and simple operation are designed to minimize operator errors and ensure the highest possible machine availability. The system has been validated in accordance with the GAMP standard, meets the highest quality standards and is also easy to clean.

“Robotec Solutions developed a system concept that is unique in its compactness, performance and user-friendliness.”

The project 

The Robotec Solutions team has built one of the most modern automation solutions for checking, filtering and packaging pipette tips in a very short space of time. The system is characterized by its modular design, the use of state-of-the-art technologies and simple operation. The Robotec team included Kevin Bossard (project management, design), Simon Rüdiger (software programming) and Livio Stocker (on-site installation, commissioning).