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How a generics manufacturer in Nairobi moved from semi-automatic blister packing and hand cartoning to an integrated BP-300, AP-400 and BL-150 line, doubling packed output and serialising every carton to shipper level.
Tablets were packed on a semi-automatic blister machine and cartoned by hand, which limited output and relied on visual checks for empty pockets. New tender contracts required GS1 DataMatrix serialisation on every carton with aggregation to shipper level, which the manual process could not provide.
An integrated packaging line: a BP-300 blister packer with vision inspection that rejects empty or broken pockets before cartoning, an AP-400 horizontal cartoner, and a BL-150 serialisation and aggregation station recording carton-to-shipper relationships. FAT was run at the Kolkata works with a recorded remote session, followed by SAT and IQ/OQ on site.
2.1×
packed output per shift
100%
of cartons serialised and aggregated to shipper level
6 weeks
from start of SAT to first tender shipment
A generics manufacturer in Nairobi supplies oral solid dosage products to public-sector tenders. New contracts required serialised packs with carton-to-shipper aggregation, and forecast volumes were beyond what the existing packing hall could produce.
| Metric | Before | After | |---|---|---| | Packed output per shift | Baseline | 2.1× baseline | | Cartons serialised and aggregated | None | 100% | | SAT start to first tender shipment | — | 6 weeks |
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