The project, which was managed by Rychiger Pharmatech AG as general contractor, had clear objectives: The new packaging system had to outperform the existing line in terms of throughput and quality. The focus was on ensuring that 70 products per minute could be packaged and that the residual oxygen content in the packaging remained constantly below 5%. In addition, all seals had to guarantee maximum security in order to optimally protect A.Vogel’s sensitive products.

A special feature of this project was the line integration of different systems and suppliers. One of the biggest challenges for the Rychiger Pharmatech team was to optimally coordinate the mechanical interfaces with the sub-suppliers. As some GMP-relevant parameters of the old system could not be transferred to the new one, Rychiger’s engineering team had to ensure that the new system was flexible enough to operate without delays during commissioning. This challenge was successfully overcome and the flexibility of the system allows for a seamless transition into A.Vogel’s production processes.

The close collaboration between Rychiger and A.Vogel was key to the success of the project. Regular follow-ups and intensive coordination with the qualification and production teams on both sides ensured that potential problems were recognised and resolved at an early stage. The customer was heavily involved in the project from the outset, taking part in acceptance tests at subcontractors and regularly visiting the plant in Frauenfeld to assess progress and ensure that the high quality requirements were being met.

The FAT, which lasted four days, was a complete success. ‘We were able to impressively demonstrate to the customer that the line fulfils all the required performance requirements,’ reports Kevin Frey, Project Manager at Rychiger Pharmatech AG. During the lengthy test runs, further optimisation potential was also identified, which will now be adjusted before the final commissioning. This iterative process helps to ensure that the system is perfectly customised to A.Vogel’s needs when it is finally installed on site.

The new packaging line will almost fourfold A.Vogel’s production capacity and ensure a higher standard of quality in production thanks to automation. ‘This system will optimise A.Vogel’s processes in the long term and help them to fill their products more efficiently and safely,’ explains Kevin Frey. The partnership between the two companies has once again proved its worth and Rychiger hopes to continue working with A.Vogel on future projects.

For Kevin Frey, the success of this project is proof of how crucial teamwork is for complex projects. ‘Successfully completing such a large project always shows me how important it is to work as a team. The team did a great job here and supported each other to fulfil the customer’s requirements and also meet our deadlines.’

The successful FAT and the close collaboration between Rychiger Pharmatech and A.Vogel marks another milestone in the long-standing partnership. The new plant will ensure that A.Vogel can continue to fulfil its high quality and efficiency standards in the future – thanks to the excellent performance of the Rychiger team.