WACKERSDORF, GERMANY — Injection molder Gerresheimer AG has started the production of components for a new order of insulin pens for Paris-based healthcare company Sanofi SA.
The preparations for the production – including the construction of a new production hall at Gerresheimer's facility in Horšovský Týn, Czech Republic, as well as all required qualifications and validations – were completed within 18 months.
The structural components for the disposable insulin pen manufactured in the new hall consist of several plastic parts which were manufactured by Gerresheimer at Medical Plastic Systems, and a bought-in bending spring. The final pen assembly is carried out at Sanofi's facility in Frankfurt/Main in Germany.
The production and assembly of the structural components involves injection moulding machines, removal robots, different measuring and testing systems as well as pad printing lines. The complex and highly automated assembly line with several assembly and testing stations was planned and installed by Gerresheimer Medical Plastic Systems, who also developed several of the required moulds.
Especially for this project, Gerresheimer built a new hall with 3,500 square meter clean room areas conforming to to ISO class 8 for production and assembly, as well as a fully automatic high-rack storage facility.
Carsten Dormeier, project manager at Gerresheimer's technical competence center said: : "We were able to adhere to the ambitious schedule of this extensive project from the start of the planning phase in Wackersdorf through to production startup in Horšovský Týn thanks to the high commitment of our staff at both facilities."
The new project is the second Sanofi order for the production of insulin pens from Gerresheimer. Reusable pens are already manufactured at the company's Pfreimd facility.