In a world that is constantly evolving, technology has taken center stage, changing industries at a pace few could have predicted. For the pharmaceutical sector—long considered slow to adopt new technologies—the winds of change are finally blowing. Robots, once thought of as tools for high-tech industries like automotive manufacturing, are now stepping into the pharma world, offering both exciting opportunities and significant challenges.
But is pharma ready for robots? Are these machines set to revolutionize pharmaceutical manufacturing, or are there hurdles that still stand in the way? In this article, we delve into these questions with insights from Daniel Sturm, Global Product Manager for Automation at Syntegon, as he explores the intricate relationship between robotics and pharma.
Robots in Pharma: Moving Beyond Science Fiction
Robots have always captured our imaginations, whether it’s Wall-E cleaning up the Earth or the Terminator causing mayhem. But in the pharmaceutical industry, robots are anything but science fiction. They are practical, precise, and efficient machines, designed for tasks that require absolute accuracy.
“Forget the images of robots you see in movies,” says Daniel Sturm. “The robots we use in pharmaceutical environments are specifically designed to improve productivity and consistency. We’re talking about machines that can take on highly specialized roles, enhancing the speed and safety of drug production.”
And what makes these robots unique? It all starts with the axes.
Understanding the Role of Axes in Robotics
When discussing robotics, you’ll often hear about "four-axis" or "six-axis" robots, but what does that really mean? The term “axis” refers to the degree of freedom a robotic arm can move in. The axes determine the robot’s ability to move in different directions, with each additional axis adding more flexibility and range of movement. “You can think of a robot’s axes like a human’s limbs and joints,” Sturm says. “The more axes a robot has, the more tasks it can perform and the more complex its movements.”
In pharmaceutical manufacturing, this flexibility is key. Four-axis robots are commonly used for their ability to handle repetitive and straightforward tasks, while six-axis robots offer more versatility for intricate jobs. These robots are integrated into everything from packaging lines to gloveless filling systems, where they help maintain cleanroom standards.
Annex 1 and the Drive Toward Automation
One of the main drivers behind the increasing use of robotics in pharma is regulatory pressure. The new Annex 1 guidelines from the European Union’s Good Manufacturing Practice (GMP) have placed greater emphasis on hygienic design and automation. According to Sturm, these guidelines are pushing pharmaceutical companies to rethink their production processes.
“Annex 1 is really the catalyst here,” he notes. “The guidelines encourage the use of appropriate technologies—like robotics—that minimize or even eliminate human intervention in aseptic manufacturing. This reduces contamination risks and makes the entire process safer for both the operators and the product.”
But adopting robots in such a regulated environment isn’t without its challenges. For all their benefits, robots in pharma face several hurdles. One of the biggest concerns is cleanroom compatibility. Pharmaceutical environments require machines that meet strict hygienic standards, and traditional robots often come with risks in contamination, which could compromise sterile conditions.
“The challenge with robots in pharma is ensuring they are cleanroom compatible,” Sturm explains. “Robots need lubrication, they generate particles, and they can introduce contamination risks if not designed correctly. But with advancements in hygienic design, we’re seeing more robots that are suitable for these sensitive environments.”
Another key issue is safety. Large six-axis robots can be powerful and potentially dangerous if not equipped with the right safety features. Ensuring that these machines can operate safely around human workers is a top priority, particularly in environments where precise movements and interactions are critical.
Syntegon’s Role in Shaping the Future
Syntegon has been at the forefront of integrating robotics into pharmaceutical manufacturing, developing its own four-axis robotic solutions to enhance packaging flexibility and efficiency. Their patented robots are not only highly adaptable, but they also reduce the need for multiple format parts, streamlining production and minimizing downtime.
One of Syntegon’s standout innovations is the use of gloveless technology. By incorporating robots into their systems, they have eliminated the need for human operators to manually intervene in sterile environments, drastically reducing contamination risks.
“We’ve been using robots for a long time,” says Sturm. “Our four-axis technology has become a core component of our machines, offering flexibility and reducing format parts. This enables us to adapt to different production needs more quickly and with fewer risks.”
The Pandemic’s Role in Accelerating Robotics Adoption
The COVID-19 pandemic put a spotlight on the benefits of automation, not just in pharma, but across all industries. With many workers sick or quarantined, robots became an attractive alternative to manual labor. Robots don’t get sick, they don’t require rest, and they can work 24/7, making them ideal for industries that can’t afford interruptions.
“The pandemic was a turning point,” Sturm reflects. “It showed us that robots are not just a luxury—they’re a necessity. The pharmaceutical industry, which has traditionally been slow to adopt automation, is now realizing the importance of having a resilient and adaptable manufacturing system. And that’s where robots come in.”
What’s Next for Pharma and Robotics?
Looking ahead, the future of robotics in pharmaceutical manufacturing looks bright. As companies continue to invest in automation, the potential for robots to take on even more roles—both inside and outside the machine—is vast. From transferring materials in cleanrooms to operating complex machinery, robots are poised to play an even bigger role in pharma’s future.
Coupled with AI, robotics promises transformative advancements, driving highly adaptive and efficient production processes through predictive analytics and intelligent automation. These technologies are set to revolutionize drug manufacturing by enhancing quality control, streamlining workflows, and enabling groundbreaking innovations such as gloveless isolators and fully integrated digital twins. However, the integration of AI introduces both opportunities and challenges.
Robotics are not just the future of pharmaceutical manufacturing—they are the present. With companies like Syntegon leading the way, robots are helping to revolutionize the industry by improving efficiency, safety, and flexibility. As the sector continues to navigate regulatory landscapes and technological advancements, one thing is clear: the future of pharma is automated, and robots are here to stay.