Ascential's experienced team has successfully completed hundreds of projects in the production of medical devices, pharmaceuticals, and other life science products. We understand how to achieve the most out of modular automation systems for performance with complex products, and to ingeniously design them to scale with ease as production needs expand.
The core of modular automation is the use of equipment and machinery that can be easily reconfigured or adapted for different processes or products. These modular units can include robotics, conveyors, filling systems, and more.
Tooling and fixtures that can be quickly swapped out or adjusted to accommodate different product sizes or configurations. This allows for rapid changeovers and reduces downtime.
Centralized control systems, often based on programmable logic controllers (PLCs) or supervisory control and data acquisition (SCADA) systems, manage and coordinate the various modules and processes within the manufacturing line.
Sensors and Monitoring
An array of sensors and monitoring devices are used to collect data on process parameters, product quality, and equipment performance. This data is often used for real-time quality control and process optimization.
Human-Machine Interfaces (HMIs)
User-friendly interfaces that allow operators to interact with and monitor the system. HMIs provide real-time data visualization and control, enabling operators to make informed decisions.
Conveyors and Transport Systems
Automated conveyors and transport systems facilitate the movement of materials and products between different modules or processing stations. These systems are often designed to accommodate various product sizes and shapes.
Robotics and Pick-and-Place Systems
Robots and automated pick-and-place systems handle tasks such as material loading, assembly, inspection, and packaging. They are highly adaptable and can be reprogrammed for different tasks.
In medical and pharmaceutical manufacturing, cleanroom environments are essential for maintaining product sterility and quality. Modular automation systems may include cleanroom enclosures or environments designed for specific cleanliness levels.
Quality Control and Inspection Stations
Integrated inspection and testing stations ensure that products meet quality standards. Vision systems, sensors, and automated inspection tools are commonly used for quality control.
Data Integration and Analytics
Data from various sensors and control systems are integrated into a centralized database. Advanced analytics and machine learning algorithms may be applied to analyze this data for process optimization and predictive maintenance.
Maintenance and Serviceability
Modular automation systems are designed with ease of maintenance in mind. Components can be replaced or serviced without disrupting the entire system, minimizing downtime.