Case Study: Fresenius 

Business Challenges

  • Flexibility of the packaging line was needed for numerous products to be processed in different sized order batches
  • Fresenius required several quality inspection procedures on their products before they were palletized and shipped to their customer

Fresenius Medical Care

Fresenius Medical Care is a leading manufacturer and distributor of a wide variety of dialysis products.  A global leader, Fresenius provides the highest quality standards in the industry.  


Key Technologies

  • Two (2) robotic series 4000 conventional palletizers running at 23 cases per minute
  • Hytrol "Gen 3" zero pressure accumulation conveyor
  • Counter-balanced power roller gates
  • Itoh Denki powered rollers and right angle transfers
  • Mettler Toledo high speed check weighing system
  • Zebra Overture ink jet label application system
  • LabelJet/Sato print and apply system
  • PSI dispensers for automated insertion of the packing list
  • 3M fully automatic carton tapers
  • Human Machine Interface (HMI) and control system


  • Bastian provided a complete system that allowed Fresenius to simultaneously pack two different products for redundancy and increased throughput
  • Product integrity was maintained by utilizing a bi-directional conveyor system and line setup with safeguards embedded in the control system
  • The controls system allows for centralized control and automated quality check interlocks for quick line changeover
  • The new system processes orders 2 times faster than the previous system

Photos of our solution

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