The 21st Century Intelligent OSD Factory

Project Time:2024
Amid the global pharmaceutical industry's accelerated shift toward intelligent transformation, AUSTAR Group has partnered with a leading Pharmaceutical company to establish an FDA- and cGMP-compliant oral solid dosage (OSD) production facility with an annual capacity of 10 billion tablets. This project marks a significant leap from traditional manufacturing to digitalized, automated management, driven by cutting-edge technologies such as the Material Control System (MCS) and Automated Guided Vehicle (AGV) systems, setting a benchmark for efficient, compliant, and sustainable intelligent production.

AUSTAR Solution

Automatic unpacking, material identification, coding, automatic transmission and transportation, material purification, crushing and screening, automatic weighing system, AGV automatic transportation, and integrates MES, material control system, WCS system, AGV scheduling system, forming an integrated solution with a single shift processing capacity of 35 tons and 40 kinds of materials identification, unpacking, coding, transmission, purification, crushing, screening, weighing, AGV transportation, etc. The whole project involved various packaging forms visible in the industry, and provided client with intelligent and information-based automatic material weighing and transfer system to realize unmanned production of formula transfer system.

AUSTAR Value & Client Benefits

MCS System: End-to-End Material Lifecycle Tracking. • As the "central nervous system" of the factory, the MCS system integrates the entire process management of materials from receipt, weighing, transportation to cleaning. The system monitors the status of all material bins (BIN) in real-time (in use/ready for use/awaiting cleaning/cleaned) and their internal batch information, seamlessly connecting with production orders. Eleven AGV robots form the factory's "flexible logistics network," covering four production floors and achieving fully automated material transportation. • Intelligent Path Planning: AGVs autonomously avoid obstacles and optimize routes based on MCS instructions, increasing efficiency by 60% compared to traditional manual methods. • Multi-Task Coordination: After completing raw material feeding, AGVs simultaneously collect empty bins and transport them to the washing station, ensuring continuous production. • Heavy Load Capacity: With the support of inter-floor and heavy-load elevators, the system enables large-capacity BINs to be transported across floors for feeding, meeting the high-yield requirements of solid dosage forms.

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