Synthesis Alfa FS: Universal Pack Pharmaceutical Complete Line for Stick Packs in Cartons
A complete line designed to take the product all the way to the finished pack
Synthesis Alfa FS clearly represents the concept of an integrated line applied to pharmaceutical packaging. Rather than a simple sequence of machines, it is a complete system in which primary packaging, counting, transfer and cartoning are developed to operate as one continuous process.
In pharma applications for stick packs in cartons, the primary machine feeds a patented counting & stacking unit, which transfers the stick packs to the secondary packaging section. In the case of flat blank cartons, insertion is carried out in top loading, between the carton forming and closing stations.
One of the line’s distinctive features is precisely this level of integration. The entire system is designed to ensure process continuity, ease of operation and coordination between the different stages. Added to this is the advantage of relying on a single supplier for the complete line, while still allowing the integration of third-party machines when required.
The design logic behind the line
In the specific case of Synthesis Alfa FS for pharmaceutical applications, the final result is generated by the precise interaction of several line units, each performing a defined function within a continuous flow.
In a case history focused on the packaging of pharmaceutical powders and granules, the configuration includes:
- Stick pack machine;
- Counting & stacking unit with a delta robot system for top loading;
- Carton forming and closing machine;
- End-of-line module for production controls and serialization.
As a whole, the line is configured to place stick packs into cartons of different sizes, manage variable counts and maintain a fully automated process from the primary pack to the finished product.
From Stick Packs to Cartons
The stick pack machine: the core of primary packaging
At the heart of Synthesis Alfa FS is the stick pack machine, responsible for forming the primary pack and dosing the product. In pharmaceutical applications, this type of machine is designed for single-dose packaging and can be integrated into cartoning lines with a high degree of flexibility, making it possible to manage different pack counts within the same carton.
For powders and granules, the line can adopt either auger or volumetric cup dosing systems, selected according to the characteristics of the product. The auger system is suited to poorly flowing or sticky powders, while the volumetric cup system is more appropriate where speed and continuity are required for freer-flowing powders and granules.
The counting & stacking unit: the link between primary and secondary packaging
After primary packaging, the stick packs are conveyed to the counting & stacking unit, which acts as the link between sachet production and final carton loading.
This section is responsible for counting, arranging and positioning the stick packs according to the required configuration. The system can be adapted according to the number of packs per carton, pack orientation and the transfer logic toward the cartoner. In flat blank carton configurations, the unit feeds the top-loading section. In other applications, it can also support more advanced solutions such as on-edge placement or multi-level cartoning.
The delta robot system: precision in the transfer to the carton
In the pharmaceutical configuration, the counting & stacking unit is combined with a delta robot system, in which the insertion of the stick packs into the carton is carried out by robotic arms.
This is a key stage in the process, because it converts a continuous sequence of stick packs into an ordered, consistent flow synchronized with the following cartoning operations. It is at this point that the precision of the primary packaging stage is translated into loading accuracy, operational continuity and reliability in secondary packaging.
Forming and closing flat blank cartons
The final part of the line is dedicated to forming and closing flat blank cartons.
In lines for flat blank cartons, the cartoner is divided into two separate sections: one for carton erection by means of a mechanical former and hot-melt glue, and one for final closing through tuck-in and hot-melt application. In this architecture, the stick packs are inserted between the two stations, following a linear logic that supports process continuity and control. The platform also allows different carton formats to be handled, with good accessibility and quick format changeovers.
End of line: production controls and serialization
The end-of-line module is dedicated to production controls and serialization.
At this stage, devices such as a carton barcode reader, leaflet folding and inserting device, track & trace systems and serialization functions can be integrated. The result is not simply a closed carton, but a finished pack already prepared to meet market requirements, traceability standards and the compliance needs typical of the pharmaceutical sector.
The pharmaceutical technologies that define Synthesis Alfa FS
Powder handling and dosing accuracy
In pharmaceutical packaging, line quality also depends on the ability to adapt to the behaviour of the product itself. For this reason, powders can be handled using auger or volumetric cup dosing systems, selected according to the flow properties and physical characteristics of the formulation.
To support dosing accuracy, the line can integrate high-precision weighing cells with feedback to the dosing unit, allowing deviations to be corrected quickly, together with automatic rejection systems for non-compliant packs. This brings quality control directly into the process.
Protection of heat-sensitive products and sealing control
When heat-sensitive products are involved, thermal stability becomes a critical factor. For these applications, the line can be equipped with cooling systems for heat-sensitive powders, designed to keep the temperature of the sealing block under control.
This is combined with accurate sealing temperature management throughout the sealing block by means of sensors and distributed control systems. The result is greater product protection and more consistent pack quality.
Data control, traceability and compliance
From a digital and regulatory perspective, the line can integrate tools for data control, traceability and compliance, including OCR/OCV, 21 CFR Part 11, audit trail, OPC UA, batch management, serialization and validation documentation.
The configuration may also include accessories such as checkweighers, leaflet insertion, tamper-evident labelling and in-line weight control, with automatic rejection of non-compliant cartons.
Not just a packaging machine
The structure and operation of the line, through its units, mechanisms and integrated technologies, clearly reflect a design approach focused on the final result and on the quality of the entire packaging process.
See Synthesis Alfa FS live at Interpack 2026 and meet our team to explore the line up close.
