How We Automated Syringe Packaging and Inspection for a Top-5 Pharma Company
The Challenge
A leading pharmaceutical manufacturer was packaging 1ml syringes into rondo trays entirely by hand. Technicians spent hours each day picking syringes, visually inspecting them for defects, orienting them correctly, and placing them into trays. The work was repetitive, physically taxing, and error-prone. Missed defects meant quality issues downstream. Fatigue meant inconsistency. And the process couldn't scale without adding more manual labor.
The company needed a solution that could inspect every syringe with consistent accuracy, handle the precise orientation and placement into rondo trays, and operate alongside existing technicians on the production floor — without disrupting their established workflow.
The Solution
We configured a Dorna Lab Automation System specifically for this workflow. The system uses AI-powered machine vision to inspect each syringe for defects. A precision pick-and-place module handles the physical packaging with the speed and consistency that manual handling can't match.
The project moved from initial scoping to deployment in weeks — not months. Our engineering team handled the integration and fine-tuning on-site, working closely with the customer's production team to ensure the system fit seamlessly into their existing floor layout and workflow.
The Deployment
What makes this project especially noteworthy is how smoothly the system integrated into a real production environment. The system operates alongside technicians — not in a separate room or behind a cage. It's compact enough to sit on the production floor without displacing existing equipment, and intuitive enough that operators were trained in a single session.
The system is now running in production, handling inspection and packaging with a level of consistency that manual processing couldn't achieve.
The Result
- Consistent, AI-driven inspection on every single syringe — no spot checks, no missed defects
- Reduced physical strain on technicians previously doing repetitive manual packing for hours
- Faster throughput with higher accuracy than manual handling
- Compact benchtop footprint that fits into the existing production floor layout
What This Means for Your Lab
This project demonstrates what Dorna's modular platform can do when applied to a real production challenge. The same platform that handles syringe packaging can be configured for tube labeling, sample preparation, or any other multi-step lab workflow. If your team is spending hours on repetitive, manual tasks that demand precision and consistency, there's a better way.