Agile Small to Medium Batch Production Enabled by XPlanar Technology

How LSS partnered with an international CDMO to remove bottlenecks, accelerate format changes and future proof their production line.

Discover how, together with the customer, we developed one line for multiple packaging patterns – with maximum agility for small to medium batches, fast changeovers, full traceability and readiness for future formats.

Listening First: Understanding the Customer’s Operational Barriers

Through a structured requirements phase, we worked closely with the customer’s production and engineering teams to understand the full scope of their operational challenges:

• Long changeover times between formats, especially when switching between primary container types
• Space consuming manual handling activities that carried a risk of human error
• Increasing demand from global pharma clients for rapid onboarding of new formats
• Time-consuming batch change and line clearance procedures
• Increasing need for integrated quality control and digital traceability

During the requirement analysis, we worked closely with the customer to map every packaging format they needed to support. These included foil trays and cartons—both top‑ and side‑loaded—along with the option to place leaflets either at the top or bottom of the pack. 

The same primary product, such as a vial, syringe or pen/auto‑injector, could therefore require multiple packaging combinations such as: 

• Varying numbers of leaflets 
• Different cartons and loading directions
• Glued or tamper‑evident sealing

To support very small batches, the solution also has an integrated manual packing station that maintains full GMP compliance.

This joint exploration of packaging formats gave both parties a clear view of the complexity involved and strengthened confidence that a conventional conveyor based solution would not be sufficient.

Our Solution: A Fully Made-To-Measure XPlanar-Based Platform

This extensive variability in formats was far beyond the capabilities of what one line with traditional transport and handling systems can offer. By contrast, the XPlanar‑based solution allows the customer to define pack formats batch‑by‑batch and adjust the sequence in which components are introduced, ensuring true scalability across current and future requirements.

Together with the customer, we designed and built a highly flexible solution based on Beckhoff’s XPlanar intelligent transport system. The floating movers and tile based modular design enabled us to create a platform that supports dynamic routing, parallel workflows and rapid format reconfiguration – capabilities not possible with traditional conveyor based systems.

The result is a compact (7,5m long), GMP aligned solution engineered specifically for the realities of modern CDMO production, where agility and compliance must go hand in hand.