Offline Pharmaceutical Serialization System

Offline Pharmaceutical Serialization System – Electrical & Automation Design

I engineered and delivered the full electrical, control and verification system for this offline serialization unit—purpose-built for empty pharma cartons before the packaging stage. I led the design, integration and commissioning, bringing together printing, vision, and reject systems into one self-contained and high-precision solution

Overview

This standalone module enables accurate printing and real-time verification of DataMatrix codes on empty pharmaceutical cartons—independent of the main production line
It stands apart from the online version by focusing on batch preparation, pre-serialization, and re-work workflows, providing flexibility and traceability for the pharmaceutical packaging process

Mechanical & Printing Structure

At the heart of the system is a vacuum-belt conveyor with perforated surface and suction system for firm carton positioning. This ensures vibration-free printing and stable code placement even at high speed. The unit is designed to be compact, operator-friendly, and integrates easily with various printer models and vision modules

Printing & Verification

I configured the unit with HSA TIJ (Thermal Inkjet) printers, operating on HP TIJ technology, to print DataMatrix codes directly on cartons. A vision camera captures each print and verifies code integrity in real-time. Any unreadable or invalid carton is automatically rejected, guaranteeing only verified items move forward

Electrical & Control Design

I led the entire electrical system design—from panel architecture to wiring, component selection (FATEK, Schneider, Omron, Tele, Pepperl+Fuchs) through to control logic. Using EPLAN for all schematics, I ensured full serviceability and future-proofing. The control logic allows for high precision, operator safety, clear alarm diagnostics, and parameter tuning via HMI.

My Role & Vision

As the electrical designer and system integrator, I oversaw end-to-end development: from early prototyping through installation and on-site debugging. I coordinated with mechanical and software teams, ensuring synchronization between print, vision and reject systems. This machine embodies my aim: to build locally engineered solutions with industrial-grade reliability, precision and modern control architecture—serving the pharmaceutical sector