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The proces
Vials enter the machine from the inspection line and are arranged into straight, evenly counted rows on a sliding plate. While this happens, the SCARA robot picks a flat tray from one of the two magazines and pre‑folds it in one of the folding stations.
Once a full set of vial rows is formed into a layer, the machine pushes them in one motion into the pre‑folded tray. The tray is then fully folded and closed automatically.
Next, the tray passes through the banding unit, where two printed bands are applied and verified by a vision camera. Finally, the finished tray moves to the palletizing module, where a Cobot picks and stacks it onto a pallet according to a defined pattern.
How it works
The Tray Loader integrates advanced robotics and automation into a seamless production flow:
- Vial handling system – Automatically feeds and pre-positions vials into precise rows for consistent loading into trays.
- SCARA robot – Picks flat trays from the magazine, performs tray handling, folding assistance and transports filled trays through the machine.
- Dual tray stations – Two parallel folding and filling positions allow simultaneous processing for increased efficiency.
- Banding & vision system – Applies two bands with printed data and verifies each print using an integrated camera system.
- Cobot palletising – Picks trays from the outfeed conveyor and stacks them on pallets in a predefined pattern, with two pallet positions for continuous operation.
Every step of the process is controlled via HMI, sensors and safety systems to ensure consistent performance and operator safety.
Key features
- Automatic tray folding & vial loading – Handles complete tray forming, filling and closing in one process
- Layer-based loading – Inserts complete vial layers in one controlled movement for high efficiency
- Compact footprint – Integrated design with main machine and palletise
- User-friendly interface – HMI with recipe management, batch control and diagnostics
- Advanced safety – Emergency stops, safety interlocks doors and LOTO systems
- Flexible operation – Automatic vial infeed with optional manual feeding
- Continuous production – Dual tray drawers for uninterrupted operation → filling of tray magazines during production
- High automation level – Fully integrated robotic handling and palletising
- Integrated banding & printing – Automatic banding system (Bandall) with inline printing
- Temporary storage – Suitable for cooled or controlled environments
Why choose the Trayloader?
The Tray Loader offers an optimal balance between process reliability, flexibility and automation. The fully recipe-driven system guarantees consistent handling for multiple vial sizes while reducing manual intervention.
Its modular design and compact layout make it easy to integrate into existing production lines.
- Fully automated process – From vial infeed to palletising in one integrated system
- High flexibility – Supports multiple vial formats with fast changeover (< 1 hour)
- Integrated quality control – Vision system ensures correct print verification
- Continuous production – Dual tray magazines allow refilling during operation
- Reliable performance – Recipe-driven control ensures repeatable and consistent results
Why choose GTE Engineering?
GTE specialises in designing and producing tailor-made machines for the medical and pharmaceutical industry. Based on your specific needs, we’ll work together on the solutions to the issues you’ve run into.
Curious about what we could do for you?
Engineered for Performance
Technical highlights
- Dimensions: 5000 mm (L) × 3200 mm (W) × 2600 mm (H)
- Throughput: up to 400 vials per minute (depending on product type)
Applications
- Pharmaceutical manufacturing
- Life sciences production
- Medical packaging lines
- High‑precision vial handling
- Automated tray loading and palletising processes
Ready to optimise your packaging process?
Looking to increase efficiency, reduce manual handling and ensure consistent quality?
Get in touch and discover how the Automatic Tray Loader can streamline your production line.
Let’s automate your packaging process.
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