John Kehoe
Innovations Director, Tekpak Automation
Company founder and now concentrating on R&D and technical innovations as well as M&A activities
Taigh Connor Watson
Operations Director, Tekpak Automation
Highly experienced engineer with a background in pharma manufacturing, having worked for many years at GSK (GlaxoSmithKline) in their UK manufacturing operations
Frankie Rose
Technical Sales Manager, Tekpak Automation
Recently returned to Tekpak after a brief period where he was involved with a different venture. Frankie has over 10 years’ experience working in Tekpak in areas including design, operations and technical sales.
Tekpak has been manufacturing complex robot-based packaging machinery for the Food and Pharmaceutical Industries for almost 25 years, becoming Ireland’s leading packaging automation company.
Ireland is a small country with a big pharma industry. It’s the world’s third-largest exporter of pharmaceuticals and serves as a major hub for biopharmaceutical manufacturing. This makes it the ideal headquarters for Tekpak, a Wexford-based high-tech automation company that designs and builds high-speed complex machinery that picks, wraps, packs and stacks food and pharma products into trays, cartons, cases and pallets.
Tekpak has been making world-class packaging automation equipment for almost 25 years, designing and manufacturing full lines with an array of packaging capabilities. These include robotic pick and place, filling, wrapping, labelling, tray loading and unloading, horizontal and top-load cartoning, tray de-nesting and re-nesting, product stacking, case packing and palletising.
Customisable, flexible and compact solutions
“Tekpak is unique in Ireland because we are exclusively focused on Packaging Line Automation, and these world-class machines are designed and manufactured here. We take turn-key responsibility for full packaging lines tailored to the needs of our customers, both at home and internationally,” says John Kehoe, Innovations Director, Tekpak Automation. “Where necessary, we design and manufacture completely new and unique packaging machines. We also have a series of standard modular systems, that are quickly and fully customisable to specific requirements and space constraints.”
Tekpak’s technical experts handle every aspect of a project, from design, fabrication, software and commissioning to validation and handover. By utilising the latest digital twin technology, the company can create solutions with shorter lead-times.
Because Tekpak’s technology is mainly robot-based, it’s extremely flexible. It can run at very high speeds and change format incredibly quickly. “Traditionally, it would take an hour or two to complete a full changeover on an entire packaging line,” notes Frankie Rose, Technical Sales Manager, Tekpak Automation. “But fully automatic change can be achieved with our machines within two to three minutes.”
AI-enabled cameras, sensors and other Industry 4.0 technologies can be used for
quality control purposes and to verify that line clearance operations have been performed correctly.
Industry 4.0-ready tech for real-time insights
All machines are provided with Industry 4.0-ready options, so they seamlessly integrate with other devices and higher-level SCADA, MES and OEE systems, generating data and communicating with each other to provide pharma manufacturers with real-time insights that improve operational efficiency. For example, AI-enabled cameras, sensors and other Industry 4.0 technologies can be used for quality control purposes and to verify that line clearance operations have been performed correctly.
All Tekpak machines are supplied with software tools that provide 21CFR Part 11 compliance and are built according to Good Automated Manufacturing Practices (GAMP) guidelines. Additionally, control systems can be specified to provide an audit log, time synchronisation, Active Directory for user authentication and user groups and permissions.
This means clients can be reassured they’re receiving not only high-speed, reliable equipment but also the documentation and validation services necessary for full regulatory compliance. “We’ve developed a deep understanding of the needs of our multinational clients, especially those in the pharmaceutical sector,” says Taigh Connor-Watson, Operations Director, Tekpak. “Our project and design teams all receive training regarding constantly changing regulatory requirements.”
Once the machinery is delivered and installed, Tekpak has a dedicated technical support team on standby with guaranteed fast response times. “Our work isn’t just about design, build and implementation,” says Kehoe. “It’s about collaborating closely with our clients to ensure all project deliverables are completed to the highest possible standards.”
PHARMA IN IRELAND — AT A GLANCE
• It’s projected that revenue in the Irish pharmaceuticals market will reach US$2.40bn in 2025. (Statistica)
• Ireland is home to more than 90 pharmaceutical companies and employs around 50,000 people countrywide. (IDA Ireland)
• Nine of the world’s top 10 pharma companies have established significant operations in Ireland. (IDA Ireland)
WHY TEKPAK?
• Full Line Capability – manufactured in Ireland
• In-house packaging and automation expertise, with proven expertise in life sciences and high-volume food manufacturing
• All machines built in compliance with 21 CFR 11/EU annexe 11 regulations
• IOT 4.0 features available on all machines
• Fast turnaround with proven technology, agile project management, and Irish-based service department
• Full project control from design to delivery
