Pharmaceutical and Medical

Pill Production

Solutions for the Pharmaceutical and Medical Industries

Around the world, companies operating in the pharmaceutical, biotech, and medical manufacturing industries rely on Banner Engineering for our industry knowledge, experience and expertise to provide products and solutions that improve automation efficiency, maintain product quality, and protect operator safety.

We are experts in advanced optics, LED, laser, and photoelectric circuits, offering sensors for tablet fill level monitoring and count verification, cap and closure inspection, print and label verification, and product identification and serialization. We have the industry’s most complete family of safeguarding devices, allowing customers to design the highest level of safety into a machine, without compromising productivity. LED products from Banner provide clear status indication and bright, uniform illumination for machines, processes and workstations. We have a complete line-up of actuators, ideal for medical assembly, medical kitting and storage retrieval systems. Our proprietary wireless products enable the monitoring of critical sensing points for flow, level, temperature and other processes on remote assets. For demanding environments, we offer a number of products designed for high pressure wash-down, Clean-in-Place (CIP), Sterile-in-Place (SIP), chemical resistance (Ecolab Certified), and hazardous areas.

Segments of the Pharmaceutical and Medical Industry

Primary Pharmaceutical Packaging
Primary Pharmaceutical Packaging

In the pharmaceutical industry, filling the correct amount of solid or liquid products into the correct container is critical. With different drug delivery methods and packaging schemes, companies rely on banner sensors to ensure that the proper amounts of the right products are packaged correctly.

Secondary Pharmaceutical Packaging
Secondary Pharmaceutical Packaging

From ensuring caps are in place and labels are correct to closing up cartons and loading them on pallets, Banner solutions ensure that packaging is applied properly and efficiently and that product are secure and safe for shipment.

Pharmacy Automation
Pharmacy Automation

At all levels of pharmacy automation, companies rely on Banner’s extensive industry experience, application knowledge and comprehensive product offering to solve challenging applications.

Automated Diagnostics
Automated Diagnostics

Companies operating in the laboratory automation, bio-storage, and automated diagnostic industry rely on Banner’s team of industry and application experts and our comprehensive offering of sensors, vision sensors, safety, and lighting products to solve challenging applications.

Medical Assembly
Medical Assembly

Ensuring product quality in assembly processes for medical products or kitted assemblies is critical. Banner Engineering provides products and solutions that help ensure and improve product quality as well as assembly processes and efficiency, worker experience, productivity and safety.

Success Stories

UV Barcodes for Traceability
UV Barcodes for Traceability

Before shipping to the brand assembler, a supplier of auto visors needs to verify that Data Matrix UV barcodes have been printed on each visor’s safety label. The customer turned to Banner to read invisible 2D Data Matrix barcode and send data via Ethernet IP to a PLC for traceability/error proofing.

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Temperature Sensor Detects Defrost Wires
Temperature Sensor Detects Defrost Wires

An automotive manufacturer was rejecting a supplier’s shipment of rear window assemblies due to faulty defroster grids. The supplier’s existing test procedure measured current draw across the entire heating system to detect an overall failure, but it could not detect the subtle impact of a single heating wire being broken. The window supplier partnered with a Michigan-based machine automation company to create a better test fixture—one that can verify each defrost wire heats to specification prior to shipping.

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Sensors to Measure Movement Range
Sensors to Measure Movement Range

During assembly, inspections are conducted to measure seat height adjustment, forward and rearward movement, and upright and recline motion. Two sensors are used for each inspection. The sensors are deployed off the conveyor line to ensure easy access to and the free movement of the seats. At its maximum range during inspection, a seat may be as far as a meter away from the sensors.

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Bond Wire Break Detection with a Fiber Optic Pair
Bond Wire Break Detection with a Fiber Optic Pair

Accurately detecting bonding wire breakage to reduce downtime.

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Pallet Detection for Conveyance Equipment
Pallet Detection for Conveyance Equipment

A leading manufacturer of conveying equipment designs and builds high-quality, low-cost conveyance solutions. The pallet equipment they develop is expected to reliably convey, palletize and depalletize thousands of pallets and unit loads annually. This equipment must be able to sense a wide range of different pallet types and sizes to ensure the proper packing and unpacking of pallets and avoid line slow-downs, pallet crashes and collapses.

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Detecting Parts Ejected from Die
Detecting Parts Ejected from Die

In the manufacturer's facility, operators manually insert and remove metal parts from the die press. When complete, the parts are sent into a bin via a metal chute. In order to prevent die crash (having double parts in the press at once) the customer needed a sensor that could detect various parts on the chute and send a signal to the control system, indicating that the press is free and allowing the operator to perform another stroke. The solution needed to be installed without cutting slots in the chute sides or mounting sensors at the end of the chute, which could create catch points for traveling parts.

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Operator Guidance Solution
Operator Guidance Solution

A Henshaw customer manufactures drivetrain and powertrain systems for the automotive industry. The company had experienced productivity losses due to errors in the assembly of transmission valve bodies. Henshaw was tasked with developing a system that would reduce errors and improve the assembly process.

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Radar Based Collision Avoidance in Mining Environments
Radar Based Collision Avoidance in Mining Environments

Blind spot object detection, alerting operators with time to respond

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Run Bar Provides Operator Guidance
Run Bar Provides Operator Guidance

A leading machine manufacturer builds workstations designed for accurate, timely and cost-effective battery cell assembly. A value added component of the workstations is an operator guidance device that does three jobs: enables assembly processes to start and stop, indicates parts to be picked and installed, and completely stops line operation if emergencies occur. When it became too costly for the OEM to construct and mount these devices themselves, they turned to Banner to craft an all-inclusive solution. To honor the time line requirements of their customer—a major tier two battery supplier—the OEM needed the solution in eight weeks.

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Tracking Package Location through Conveyor Roller Gaps
Tracking Package Location through Conveyor Roller Gaps

• Precise location detection</br> • High-speed conveyor</br> • Customer specific product</br>

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Zero Defect Standard on Industrial Winder
Zero Defect Standard on Industrial Winder

A successful manufacturer of specialty industrial yarns makes fiberglass and glass thread products for applications in the automotive, aerospace, military and composite materials industries. To help maintain their high standards and minimize costly product returns, they established a goal of zero product defects. To meet this goal, the company needed an automated thread inspection system.

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Preventing Shipping Errors at a Large Distribution Center
Preventing Shipping Errors at a Large Distribution Center

The customer was looking for a single-output solution that senses packages quickly, is easy to install and maintain, and was affordable enough to buy in bulk quantities if needed.

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Combined Inspections Used to Meet Quality Standards
Combined Inspections Used to Meet Quality Standards

Bottles incorrectly packed into bliss trays for sale in club stores did not properly display product labels and had to be returned to the company.

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Detecting Various Registration Marks
Detecting Various Registration Marks

Hamer, LLC is a Minnesota-based manufacturer of automated packaging equipment for a wide variety of applications and world-wide customers. From pet food to pellet fuels, Hamer machinery packages products in a variety of weights and sizes at speeds up to 60 bags per minute. A vital component of Hamer’s equipment is registration mark sensing—the ability to detect marks on packaging as it passes at high speeds. When a mark is detected, the equipment cuts the packaging at the designated location, eliminating waste and ensuring each bag is consistent.

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Simplifying Safety Feature Management [Success Story]
Simplifying Safety Feature Management [Success Story]

Algus Packaging Inc. is a leader in the heat seal and thermoform packaging industry. They design, develop and manufacture high-performance sealing machines, thermoformed packaging and offer full service contract packaging. The machinery and services offered by Algus provide their customers with the ability to change and grow as business needs dictate, now and in the future.

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Increase Drive-Thru Business with Wireless Vehicle Detection
Increase Drive-Thru Business with Wireless Vehicle Detection

Wireless vehicle detection at a quick serve restaurant drive-thru.

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Superior Light Distribution with LEDs
Superior Light Distribution with LEDs

American Hoffmann Corporation chose WLB32 LED light bars to illuminate work areas, enclosures and control cabinets, replacing fluorescent light fixtures. The superior light distribution offered by the WLB32 LED lights lights, as well as the ease of installation were key factors in the company's decision.

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Blue LED Sensor Detects Amber Bottles
Blue LED Sensor Detects Amber Bottles

A recent industry switch from polypropene (PP) to polyethylene terephthalate (PETE) bottles prompted a leading US mail-order facility to re-evaluate their fulfillment process. With over 2,000 red LED sensors to be replaced, the facility turned to Banner for a solution.

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Communication in a Busy Manufacturing Site
Communication in a Busy Manufacturing Site

As more components pass through the oven, keeping pace with the flow of items to be unloaded becomes increasingly difficult. Congestion in the sortation area builds. Items can easily be misdirected or even damaged. A pause in the flow of parts allows the unloading operator to correct mistakes and clear a pickup station. However, the distance between the unloading and loading areas as well as ambient interference from surrounding machinery complicates communication between operators.

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Accurately Measuring Bakery Ingredients
Accurately Measuring Bakery Ingredients

Baking is a mixture of creativity, precision and attention to detail. The Wilkinson Baking Company has added technical innovation to the mix. The Wilkinson Bread Bakery is a compact, completely self-contained and fully automated bread bakery. This unique machine combines technology with tradition to transform simple raw ingredients into bakery fresh bread at 40 loaves an hour.

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Cost-Effective LED Lights Replace Fluorescent Fixtures in Machine Enclosures
Cost-Effective LED Lights Replace Fluorescent Fixtures in Machine Enclosures

Customer requested lighting fixture to aid in monitoring the welding process

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Consistent Detection of Transparent Plastic Bottles Along a Conveyor Machine [Success Story]
Consistent Detection of Transparent Plastic Bottles Along a Conveyor Machine [Success Story]

A machinery company needed a sensor able to consistently detect clear PET bottles at multiple points.

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Consistent Dough Height Measurement
Consistent Dough Height Measurement

The dough for one of the company’s many popular breakfast cereals must fall within specific height parameters to ensure that it will have the perfect flake. Dough that is too thick will emerge from baking stiff and heavy. Dough that is too thin will crumble easily. This impacts the quality, taste and texture of the final product as well as product weight and packaging. Any product that does not meet the rigorous quality standards of the company will not be shipped or sold on the consumer market.

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Accurate Label Inspection
Accurate Label Inspection

The company was experiencing several quality control issues—bottles were coming off the line with missing, skewed and double labels. As a result, the customer was scrapping over 2,000 bottles a month, a process which requires them to cut out the mislabeled portion of the bottles and re-grind the plastic for reuse. Further, the labeling errors began prompting serious customer complaints. To avoid scrapping additional bottles and losing loyal customers, the company came to Banner for a label inspection solution.

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Controlling Pivot Irrigation
Controlling Pivot Irrigation

A municipality has over 30 farm fields irrigated with gray water using pivot irrigation systems. Local regulations prohibit the irrigation system from spraying over roads and ditches. The customer needs a solution that can reliably control the water flow to the end nozzle based on predetermined location coordinates.

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Measuring Turnout Time During Emergencies
Measuring Turnout Time During Emergencies

Add vehicle detection to Fire Department dispatch, reporting

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Indicate Robot Positioning
Indicate Robot Positioning

Learn now a manufacturing company used a WLS15 Pro to improve safety in their warehouse.

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High Speed Package Profiling
High Speed Package Profiling with Laser Sensors

A laser measurement solution enables high-speed package sorting in order fulfillment applications and helps drives failure rates down—ultimately saving costs and maximizing profits.

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LED Lights Used To Inspect Liquid Pharmaceuticals
LED Lights Used To Inspect Liquid Pharmaceuticals

One global provider of healthcare products had been using vision machines to detect particulates in their liquid pharmaceuticals. When the machines were no longer able to detect contaminants to the required percentage level, the company began using human visual inspections. Since many of the particulates are extremely minute, the company needed to install bright and highly uniform illumination in their work stations so operators could effectively verify the quality of products.

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Presence Detection on Rotating Lathe Turret
Presence Detection on Rotating Lathe Turret

Betty Machine chose the SureCross® DX80 FlexPower® wireless network from Banner Engineering. This versatile, highly-scalable solution is built around a Gateway capable of two-way communication with multiple end-point Nodes.

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Gravity Irrigation with Pump and Flow Control
Gravity Irrigation with Pump and Flow Control

The Gateway, or wireless network controller, monitors the water level inside the water tank. When the water level drops, a Node installed with the reservoir pumps uses its outputs to cycle the pumps on or off. A series of Nodes monitors the amount of water flowing into each orchard. A 1 Watt Data Radio connected to the Gateway transmits the data to a mobile asset or a centralized control center for data processing and billing.

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Monitoring Height of Tortilla Dough
Monitoring Height of Tortilla Dough

A US producer of authentic Mexican foods, such as tortillas and tostadas, strives to provide the best-tasting and freshest products for its consumers. In order to achieve this goal, consistency on the packaging line is key. The company was looking for a way to eliminate inconsistencies in their tortillas. Because they did not have a way to continuously monitor dough thickness on the production line, the dough nips often turned out either too high or too low, resulting in irregular tortilla sizes and weights. If a package of tortillas is under weight, it must be scrapped. In order to help eliminate waste and improve product consistency, the company worked with Banner to find a monitoring solution.

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Monitor Fill Level of Liquid in Mobile Drum
Monitor Fill Level of Liquid in Mobile Drum

The K50U wireless ultrasonic sensor was designed specifically as a non-contact level monitoring solution. Monitoring the levels of epoxy in drums during refill alerts staff of potential overflows before they become a problem.

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Measuring Wear Patterns on Conveyor Belts
Measuring Wear Patterns on Conveyor Belts

Elevators, escalators and moving sidewalks are major investments in any facility’s infrastructure. This equipment is expected to operate safely and reliably for many years and with minimal downtime for maintenance. To meet these expectations, a large-scale manufacturer of vertical and conveyor transport equipment performs rigorous tests on all system components. The data that is collected helps the company estimate component life expectancy and plan service schedules.

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Measuring the Height of Baked Bread
Measuring the Height of Baked Bread

The bakery’s multi-staged baking process begins with mixing, kneading and fermentation and completes with proofing, baking and cooling. At each stage, experienced bakers perform quality checks for appearance, texture, size and weight. Loaves that do not meet the company’s standards are rejected for consumer sales. The company needed to build-in system capabilities to help them better manage their resources and maintain quality standards.

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Inspecting Small Connectors
Inspecting Small Connectors

An automotive supply company makes a range of vehicle systems. Their seating systems combine structure and design with features that enhance comfort and safety. Weight sensors installed on the underside of the seats work in coordination with vehicle safety systems to determine the size and position of a seat occupant. These factors affect how or if airbags will be deployed in the event of an accident.

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LED Lights Illuminate Control Cabinet
LED Lights Illuminate Control Cabinet

An equipment manufacturer builds test and measurement machinery for the auto industry. Operators access machine systems through the control cabinet. Intense illumination of the cabinet facilitates machine maintenance and management. Multiple AC powered fluorescent light fixtures had been used for this task.

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Long-Lasting LEDs Install Quickly to Illuminate Web Inspection Stations
Long-Lasting LEDs Install Quickly to Illuminate Web Inspection Stations

Hermes Abrasives requested lighting to improve inspection capabilities of abrasive products.

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LED Light Bars Outshine Fluorescents, Reduce Machine Build Times & Expenses
LED Light Bars Outshine Fluorescents, Reduce Machine Build Times & Expenses

A customer requested brilliant illumination of multiple work stations

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Illumination and Indication for PCB Assembly
Illumination and Indication for PCB Assembly

Placing WLS27 Multicolor LED Strip Lights with EZ-STATUS above PCB assembly machines provides area lighting and status indication with one rugged and versatile light. Any changes in machine status cause the WLS27 to switch from illumination to indication and cover the entire machine with the corresponding color. This type of indication allows operators to focus on the task at hand without missing changes in machine status.

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Predictive Maintenance of Rotating Parts on Conveyor
Predictive Maintenance of Rotating Parts on Conveyor

Wireless monitoring of rotating parts on coal conveyors throughout a large port allows operators to utilize predictive maintenance to prevent failure and save money while reducing downtime.

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Predictive Maintenance of Motors and Gearboxes on Large Cranes
Predictive Maintenance of Motors and Gearboxes on Large Cranes [Success Story]

Wireless products enable predictive maintenance in the port industry. Motors and gearboxes on cranes are prone to high vibration and temperature which can cause them to degrade. Predictive maintenance allows employees to interfere and solve problems before they completely fail and cause unplanned downtime and lost profit.

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Warehouse Vehicle Detection with Indication
Warehouse Vehicle Detection with Indication

Vehicle detection at loading docks is complicated because sensing solutions are exposed to the elements and need to recognize a wide variety of surfaces. Rugged ultrasonic sensors work well to accurately detect the surfaces of delivery vehicles regardless of the material. Pairing with bright LED indication creates unmistakable operator guidance.

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Shopping Center Directs Vehicles to Available Parking
Shopping Center Directs Vehicles to Available Parking

Reduce vehicle congestion, wireless monitoring

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Vision Sensor to Read QR Codes
Vision Sensor to Read QR Codes

iVu Plus BCR Gen 2 with 25 mm Micro Lens replaces hand held barcode readers to collect data from dense, difficult-to-read QR codes on vehicle transmissions. A WL50S high-intensity LED spot light illuminates the target area.

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Streamlining Call for Parts or Service
Streamlining Call for Parts or Service

To improve efficiency, assemblers at work stations need a way to call for parts and service that doesn’t involve them leaving their work stations. Getting parts more quickly would improve production efficiency, and using a system of remote indicators would let the supervisors to see the status of each work station, allowing the supervisors to fix production problems quickly and to collect production metrics.

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Vent Tube Presence on Filler
Vent Tube Presence on Filler

A high-volume brewery needed a solution capable of detecting spreader washers on the vent tubes as well as loose or missing tubes. However, the movement of the rotary filler and the wet washdown environment made close proximity deployments difficult and the range required for a remote solution could compromise inspection reliability.

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Shrink Sleeve Labeling at High Speeds
Shrink Sleeve Labeling at High Speeds

A leading manufacturer of labeling equipment offers high-speed shrink sleeve label applicators designed to process 800 bottles per minute. To maximize the machine’s performance potential, the company wanted to install sensors capable of consistent detection and output for high-speed bottling.

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Remote Monitoring Calculates Machine Run Time
Remote Monitoring Calculates Machine Run Time

During normal operation, operators load a welding machine with the frame components to be welded. The customer needed accurate machine run time data to determine why production goals were not being met.

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Vibration Monitoring of Boiler Room Air Handling Unit Prevents Costly Downtime
Vibration Monitoring of Boiler Room Air Handling Unit Prevents Costly Downtime [Success Story]

Learn how the installation of Banner wireless vibration sensors and data from the DXM wireless gateway prevented unplanned downtime in this application.

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Thermal Remediation Temperature Measurement
Thermal Remediation Temperature Measurement

The EPA has placed restrictions on the use of many fumigants citing a correlation between their use and ozone depletion. As an alternative, a large-scale flour mill performs three to four thermal remediations per year to eradicate flour beetles. The temperature inside the mill is brought up to 122° F (50° C). This is done gradually to minimize equipment and building strain caused by heat expansion.

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Status Indication on Driverless Vehicles
Status Indication on Driverless Vehicles

The K50L domed 50 mm indicator light works well for status indication on autonomous shuttle buses. The buses operate on short distances in outdoor environments that exposed the bus technology to a variety of weather conditions. The rugged K50L indicators are rated IP67 and IP69K to withstand water ingress in the harsh environment.

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  1. 31 Mar - 28 Oct, 2021

    Visit Banner Engineering at Booth 753 to see our latest products and solutions in Assembly and Robotics.

  2. 27 - 29 Sep, 2021

    PACK EXPO is an innovative web-based event that allows professionals from the packaging and processing industry to connect with exhibitors and each other remotely.