An Innovative Solution for Complex Logistical Challenges
Alcon needed to optimize a production area with a dynamic storage solution. The space was already confined, so the system had to boost productivity and quality control without expanding the footprint. Traditional temporary-storage solutions couldn’t meet these constraints, or they limited production flexibility. ferag.skyfall proved to be a compact, flexible alternative instead. It intelligently uses unused building space while delivering exceptional efficiency and reliability. The system handles transport, storage, and sequencing for optimal flow management. In total, the project comprises three subsystems: a conveyor system for automated loading, a dynamic storage unit, and end-of-line equipment for packaging into cartons, including palletizing and wrapping.
Two automatic loading stations fill the pouches, which then travel to rotary conveyors for dynamic storage. The system selects each pouch on demand, based on production needs, and sends it to sequencing lines before the cartoning area. The corridor itself runs 60 meters long, 10 meters high, and just 5 meters wide. Dynamic buffers on two levels optimize that space, with a three-level sequencer below — five levels in total for storage and sequencing. This design manages more than 1,500 items per hour from production and effectively absorbs activity peaks. It also reduces repetitive tasks, streamlines flow management, and eliminates internal pallet movements, which lowers the associated risks.
Towards a Smoother Production Process
Belt conveyors feed products into the dynamic storage at up to 1,600 pieces per hour. From there, they travel to the two automatic loading stations of ferag.skyfall. Before loading, the system scans each product and places it automatically into one of the pouches. The pouch then moves to the dynamic buffer, which holds up to 2,700 pouches.
At the output, four sequencing stations direct products to one of two automatic pouch unloading stations. Together, these stations empty up to 1,500 pouches per hour and pack the products into cartons. The cartons are then sealed, palletized, and wrapped automatically, ready for shipment. This material flow maximizes efficiency, combining high production capacity with rapid responsiveness to changing demand.
The system was built for a tight infrastructure and integrates seamlessly with Alcon’s existing setup. Two things made that possible: optimizing the available height, and automating the connections between transport, storage, and sorting areas intelligently. Together, these reduced the need for manual transport and the risks that come with it.
Skyfall Pouch Sorter for Medical Device Production: Results
This Skyfall pouch sorter for medical device production runs inside a tight 60-metre corridor. It’s just 10 metres high and 5 metres wide. Two automatic loading stations feed the system. A dynamic buffer holds up to 2,700 pouches, spread across two storage levels plus a three-level sequencer. At its core, this is a dynamic buffer and sequencing system built to absorb activity peaks without slowing production. In total, the system handles more than 1,500 items per hour from production. Four sequencing stations then route products to two automatic unloading stations. Together, these stations empty up to 1,500 pouches per hour into cartons for palletizing and wrapping.
A Compact Pouch Sorter for Tight Space Installation
Alcon’s Puurs facility had only limited floor space, and that shaped the entire design. The result is a compact pouch sorter for tight space installation: just 60 metres long, 10 metres high, and only 5 metres wide. Dynamic buffers spread across two levels. Below them sits a three-level sequencer, for a total of five levels of storage and sequencing — all within that same tight footprint. The team optimized the available height instead of the floor area. That was the key to fitting the system into an already confined production space.
A Partnership Built on Trust
This project’s success rests on a trusted partnership between Alcon and Ferag, which began in 2021. Alcon was convinced by ferag.skyfall’s performance and signed the contract in November 2022. The team installed the system in Fall 2023, with production set to begin in Spring 2024.
“The collaborative partnership was exemplary, with mutual trust allowing each party to fulfill its responsibilities and achieve a shared success,” says Eric Audemars, Sales Director at Ferag. The technical solutions met Alcon’s expectations perfectly, delivering optimal results. Throughout the project, consistent transparency and adaptability enabled the development of a customized solution aligned with the client’s needs.
“Trust was established through our team’s conviction in the solution’s potential. This confidence is contagious and translates into tangible results. That’s what the client experiences throughout the project, and it’s what makes the difference,” concludes Eric Audemars.
Ferag and Alcon illustrate how cutting-edge engineering and a strong partnership can turn logistical challenges into high-performance, sustainable solutions.
Why Medical Device Manufacturers Choose a Pouch Sorter
Medical device and pharma production has its own logistics profile. Floor space on the shop floor is often tightly constrained. Every item needs to stay traceable from scan to shipment. Product mixes change frequently, and activity peaks need to be absorbed without adding headcount or floor space. A Skyfall pouch sorter for medical device production is built for exactly this environment:
- Works as a compact pouch sorter for tight space installation, using vertical building height instead of extra floor area
- Acts as a dynamic buffer and sequencing system between production and packaging, smoothing out throughput peaks
- Full item-level traceability, from scanning through to packing
- Flexible sequencing for complex, made-to-order product kits
- Reduced manual handling, lowering repetitive-task and safety risks
Plan Your Own Pouch Sorter with ferag.go
Considering a similar Skyfall pouch sorter for medical device production for your own facility? The ferag.go Pouch Sorter Configurator makes it easy. You enter a few operational inputs: throughput, product mix, and available floor space. From there, it builds a first system concept in under 10 minutes, complete with layout direction and investment orientation. The tool is free and non-binding. So it’s a quick way to check whether pouch-based automation fits your production environment, before you enter detailed engineering.
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