Thinking ahead: What to consider for automated handling trays

Marc van Keulen, lead designer, and Seán Egan, director of global marketing & VoC development, both from Nelipak Healthcare Packaging, lists design process considerations for automated handling trays.

For internal and external transportation of critical components or devices, automated handling trays play a crucial role in the automation process where speed, efficiency and high tolerances are a pre-requisite. At every step of the design process, decisions can significantly impact outcomes, creating a competitive advantage. Often there is more than one supplier of automated systems involved in decision-making related to positioning and handling of components and trays, and a well-qualified healthcare packaging partner can serve as an intermediary between all parties involved. By getting them involved in the project early, the best result can be achieved for the user and even the patient.

The first step of the handling tray design process is to identify the functionality the tray is intended for and determine specific logistics. By involving the packaging partner here, they can add maximum value by establishing where, by whom, and how the tray will be used and designing for optimal manufacturability. By visualising the complete story, requirements and even possible extra functionalities will be established. 

Some questions to answer early in the design process include:

- What will the orientation of the part and the tray in the assembly line be?

- Where, how and by whom will sterilisation and assembly be performed to create the final product?

- What kind of protection is necessary for the products or for stacking purposes (e.g. dust protection, anti-static, stability, etc.)?

- Are there options for different type of trays or end-user packs?

- What are the dimensions of the pallet that will be used for transport?

- Will transport occur by air, sea, or truck, and what are the dimensions of the transport container?

- What will the packing and storing conditions of loaded trays be like (e.g. moisture, air temperature, light, barrier bags/lidding, straps, etc.)?

- What will the inner/outer dimensions of the box be?

- What is the allowed carrying weight of the box or stack of trays?

- What tray size will fit on the existing automated line, conveyor or box, tub, crate?

- Will this be a cleanroom or non-cleanroom product?

- What will the product lifecycle be – single trip or reusable tray? If reusable, how many cycles and cleaning requirements?

- What type of validation and transit testing (drop, vibrations and compression)/conditioning/sterilisation/stacking weight/height will need to be performed?

Early on, concept sketching is recommended in order to verify the requirements and expectations of all parties involved. This creates a clear 3D visualisation of different potential variations and makes sure everyone is in agreement. This can lead to quicker response times and a smoother overall process.

Volume studies may be performed to establish the preferred orientation/stacking direction and quantities of components, allowed tolerances of tray and part positions, construction features, material options, features for ease of de-nesting, and other important factors.

All movements of the tray should be considered during all logistic steps. For instance, manual or automated, and with stoppers, grippers, suction cups and/or conveyors. It should be determined whether indentations will be necessary in the side wall for manual handling unloading the box. The handling speed of the individual trays and orientation on the conveyor should also be established, as well as quantities per tray, box, pallet or stack if required. The injection mould configuration could provide some idea for quantities or layout configurations that will result in complete packaging density. Another question to address is how the system will detect the position of the tray, for example, with light barrier, mechanical stoppers or cameras.

By working together early and assessing critical logistical factors during the design process, handling tray functionality can be optimised, and maximum value can be added along the way. Later, CAD designs will be used to finalise concepts and placement of functionality features prior to prototyping.