Three specialized partners and one integrated packaging line for Merz

 

A complete packaging line for vial packaging was recently successfully implemented for Merz Pharma GmbH & Co. KGaA at its Dessau site. The project exemplifies how close collaboration between specialized machine builders results in a high-performance, fully harmonized complete packaging line.

 

The concept, engineering and overall responsibility for the line were with Heino Ilsemann GmbH, acting as general contractor and project lead. Based on Ilsemann’s line concept, the appropriate technology partners were selected, coordinated and integrated into a complete solution. With Christ Packing Systems and Rota Verpackungstechnik, Ilsemann brought two additional German machine builders on board, each contributing with clearly defined roles and deep technical expertise in their respective fields.

 

Holistic line solution

The line covers the secondary packaging of lyophilized or liquid-filled vials into single and multi-pack cartons, as well as the end-of-line packaging of these cartons into shipping cases and the palletizing of said cases, including Track & Trace functionality. The shared objective was to realize a seamless, efficient and future-proof packaging solution that meets the high standards of pharmaceutical production at Merz.

 

Ilsemann was responsible for the design, configuration and integration of the entire line, ensuring that all machines, interfaces and processes are optimally aligned. Rota Verpackungstechnik contributed its expertise in vial labeling. The downstream cartoning of the vials into single and multi-pack cartons was carried out using Ilsemann equipment. Christ Packing Systems supplied the CaseTeq 145 case packer for the end-of-line packaging of cartons into shipping cases. The palletizing of these shipping cases was again handled by an Ilsemann palletizing system.

 

The line was further complemented by additional specialized technology partners from Germany: Deckert supplied the serialization unit, Wipotec provided the checkweighers, and Scanware served as the system supplier for all inspection cameras, including the software for the Level 1 and Level 2 Track & Trace system.

 

The long-standing, trusted collaboration between Ilsemann and Christ Packing Systems, as well as the close coordination among all parties involved, were key success factors for the smooth integration of the line. The project shows that high-performance complete packaging lines do not necessarily have to come from a single source. Strong partnerships, clear responsibilities and deep process understanding enable the realization of highly integrated lines that deliver outstanding performance, efficiency and flexibility.

 

Proven solution: Second CaseTeq 145 for Merz

For Merz, this was already the second CaseTeq 145 from Christ Packing Systems. After a case packer of this type had been successfully commissioned in 2024, the decision was made once again in favor of this solution – a clear sign of confidence in the machine‘s concept, performance and reliability.

 

In the current project, the CaseTeq 145 processes five different formats. Format changeover is completed in just 20 minutes, offering significant advantages and flexibility in day-to-day production, especially when frequent format changes are required.

 

With an infeed rate of 275 cartons per minute, the machine is designed for high throughput. At the same time, the use of servo-driven technology ensures gentle and precise product handling.

 

Track & Trace, flexibility and compact design

For this project, the CaseTeq 145 was equipped with camera systems for serialization and aggregation. A good/bad line solution at the outfeed ensures that shipping cases are reliably and safely rejected in the event of incorrect label reading.

 

In addition, a 90° turn at the outfeed was implemented to facilitate integration into downstream processes. Despite its extensive functionality, the machine features a compact design, with a footprint of just 1.970 m x 5.215 m.

 

CaseTeq 145 – designed to meet pharmaceutical requirements

The CaseTeq 145 meets the key requirements of pharmaceutical end-of-line packaging processes. These include:

• Ergonomic machine design
• Fast and easy format changeovers
• Compatibility with all common Track & Trace systems
• GMP-compliant balcony design with fully transparent doors
• Excellent accessibility for line clearance, cleaning and maintenance

These features make the CaseTeq 145 a flexible and future-proof solution for demanding end-of-line applications in the pharmaceutical industry.

 

Partnership as a success model

The project for Merz highlights the potential of collaborative partnerships between specialized machine builders. Under Ilsemann’s overall responsibility, a high-performance packaging line was created through the combined expertise of Rota Verpackungstechnik and Christ Packing Systems, with all components perfectly aligned.

For users, this model offers a high level of technical competence at every process step, maximum flexibility in the line design and a compelling alternative to traditional complete lines from a single supplier.

 

 

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About Merz

Merz is an independent, internationally active company with in-house research and development as well as sales of innovative pharmaceuticals and medical devices in the fields of aesthetics and neurology. The company’s global business focuses on medical aesthetics, neurotoxin therapy, prescription medications, as well as consumer health and beauty products.

At its production site in Dessau, located in the Biopharma Park Dessau-Roßlau, Merz has been operating for more than 20 years with a young and agile team. The site covers the entire value chain, from the production of the active ingredient botulinum neurotoxin to filling, finished product manufacturing and release testing. From Dessau, Merz supplies products to more than 70 countries worldwide, in addition to the US market.