Nextgen Medical Solution at K 2025 - Technology for Medical Production

Arburg at the K Project with Sanofi: Digital production cell for medical technology

2025-09-29 Source: Arburg 4 min Reading Time

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At K 2025, Arburg will showcase the “Nextgen Medical Solution” developed in collaboration with Sanofi and partners Hack Formenbau and HB-Therm. The turnkey production cell for injector pen caps demonstrates how early cooperation, digital networking and intelligent assistance systems can reduce costs, energy use and footprint while ensuring high part quality and productivity in medical technology.

„Nextgen Medical Solution“: At K 2025, a pioneering turnkey system based on an electric Allrounder 570 A will be producing caps for injector pens. Arburg, Hack Formenbau, HB-Therm and Sanofi worked closely together to take a holistic view of the optimisation potential.(Source: Arburg) — „Nextgen Medical Solution“: At K 2025, a pioneering turnkey system based on an electric Allrounder 570 A will be producing caps for injector pens. Arburg, Hack Formenbau, HB-Therm and Sanofi worked closely together to take a holistic view of the optimisation potential.
(Source: Arburg)

With the “Nextgen Medical Solution” project, Arburg will be demonstrating at K 2025 (Stand 13A13), using the example of the production of caps for injector pens in collaboration with the renowned OEM (Original Equipment Manufacturer) Sanofi, the enormous advantages that early cooperation between key partners can offer in the realisation of sophisticated production cells. These include cost efficiency, reduction of energy requirements and footprint, combined with high availability, productivity and part quality. This was also achieved through the digital networking of the machine, mould, automation and peripherals as well as numerous intelligent functions integrated into the Gestica control system. “Nextgen” stands for modern technology, digitalisation and bundling the comprehensive expertise of competent partners.

The pioneering turnkey system was realised with the biopharmaceutical company Sanofi, which is an R&D driven, AI-powered biopharma company committed to improving people’s lives and delivering compelling growth. Arburg (machine technology), Hack Formenbau (mould technology) and HB-Therm (temperature control units) worked closely together to take a holistic view of the optimisation potential. Cooperation along the value chain caused stunning results: The project sets a benchmark in the field of medical technology in terms of reduced total cost of ownership (TCO), rapid time to production, parametric release for the pharmaceutical industry and ease of operation.

Quickly realised — from idea to series production

A decisive criterion was to implement the turnkey system with its numerous hardware and software options as quickly as possible in order to get products ready for series production in a targeted manner. The overall responsibility for the production cell with its hard- and software lay with Arburg as the general contractor.

The production cell presented at K 2025, centred around an electric Allrounder 570 A “Comfort” with a clamping force of 2,000 kN in a clean room design, is a benchmark for medical technology. At the heart of the exhibit is an 8-cavity mould from Hack to efficiently produce injector pen caps made from medical PP in a cycle time of less than ten seconds. A suspended and therefore particularly space-saving fully integrated six-axis robot places the moulded parts separately according to cavities. If required, the operator can manually request random samples, which are then placed in a quality drawer.

Benchmark in medical technology — focus on total costs

The practical example shows that significant cost benefits can be achieved through comprehensive collaboration, project planning, early selection and requirement-specific design of the injection moulding machine, including the mould, peripherals and material. A major benefit is the consolidation of all data in the Gestica control system in combination with numerous pilot and assistance functions. All in all, these measures enable fast and safe set-up, joint maintenance management and preventive spare parts management as well as a high level of productivity. Short cycle times, consistent high component quality, perfect melt quality, and a very high overall equipment effectiveness (OEE) have been achieved. This is accompanied by a footprint of the turnkey system that is around 25 percent smaller compared to a production cell with standard automation and a six-axis robot, and around 50 percent reduction in energy consumption thanks to injection moulding machines and temperature control units designed specifically for the application. CO₂ emissions and the product carbon footprint (PCF) are also reduced.

Intelligent communication via Gestica control

The Gestica control system acts as a control centre for intelligent communication between the machine and its environment. All data, including mould sensor data, temperature control units and robotic system, is centralised here. The entire production cell can be operated centrally via the Gestica screen and indicates as soon as any anomalies are detected. This makes work easier and safer for the user. They can quickly identify and assess when action is required based on the data provided.

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Date: 08.12.2025

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The production cell for Sanofi has numerous assistants and pilots: With the “AXW Control Fill Assist”, the filling behaviour of the moulded part can be simulated directly in the machine control system, which saves a significant amount of time when setting up the mould. The “Energy Assist” automatically heats up or deactivates the cylinder module and mould in a consistent and energy-saving manner, The “Arburg Flowpilot” regulates the mould temperature. The “AXW Control Melt Assist” automatically calculates plasticising capacity utilisation and dwell times, and thanks to the “AXW Control Cycle Assist”, the control system knows the programmed cycle sequence. Unproductive times can be eliminated at the click of a button, thus reducing the cycle time and part costs. The “Pressure Pilot” in turn ensures consistent mould filling.

In a project with Hack, HB-Therm and Sanofi, Arburg will be demonstrating at K 2025, using the example of caps for injector pens, how medical products can be produced in high part quality thanks to digital networking and intelligent control functions.(Source: Arburg) — In a project with Hack, HB-Therm and Sanofi, Arburg will be demonstrating at K 2025, using the example of caps for injector pens, how medical products can be produced in high part quality thanks to digital networking and intelligent control functions.
(Source: Arburg)

Part quality monitored, documented and ensured

Assistants ensure that the complex processes are started up safely, validated and that the first good part is produced quickly.

As part of scientific process development, the operating expert first defines the process and the process window. This process window is then confirmed and reliably documented via a Design of Experiments (DoE) using an assistant. After checking the results, the operator sets the process limits in the Gestica control system.

To ensure flawless part quality, the injection moulding process and the mould are fully monitored and regulated by digital control functions. Of particular interest is the new “AXW Control Moldlife Assist” — the fully integrated Hack moldlife sense system into the Gestica controller. The integrated sensor technology monitors the mould to enable preventive measures, supports mould set-up, maintenance planning and guidance, enhancing availability, user-friendliness, and operator safety.

The parameters from the process and mould are fully monitored in the Gestica. Due to the holistic monitoring of the parameters from the process and mould in the control system further measurements can be significant reduced. The cell is “ready for parametric release,” meaning that the system is prepared for this through its features and the digital integration of peripherals.

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