Closing and labelling vial trays in one automated step

Pharmaceutical packaging lines need to combine speed, accuracy and process control without adding unnecessary handling steps.

For one of its customers, GTE Engineering developed an automated line that forms plastic trays, loads them with glass vials, closes the trays and prepares them for transport.

The final challenge was to keep each filled tray securely closed while also applying accurate, verifiable product data.

Together with Bandall, GTE integrated a solution that combines tray closure, labelling and data verification in one automated process.

From flat tray to finished vial pack

The process begins with flat plastic trays loaded into magazines.

Each tray is automatically formed before glass vials are fed into the system and placed inside. Once filled, the tray is folded closed around the vials to create a compact transport pack.

Banding material is then applied around the complete tray and sealed.

The band-like seal keeps the folded sections securely in place, preventing the tray from opening during handling, palletising or transport.

At the same time, variable data is printed directly onto the band during application.

Closing and identifying the tray with one band

The band performs two essential functions.

First, it acts as a secure closure around the folded plastic tray. The tray cannot be opened without removing or breaking the band, providing clear evidence when the pack has been accessed.

Second, it carries product-specific information such as:

• Batch codes
• Barcodes
• Production data

This removes the need to apply a separate closure and adhesive label.

The result is a streamlined packaging step in which one material secures, identifies, and helps verify the finished vial pack.

Integrated into a complete tray-loading line

The Bandall system operates as part of a wider automated process that includes:

• Tray feeding and forming
• Automatic vial loading
• Tray folding and closing
• Band application
• Variable data printing
• Vision verification
• Rejection of non-conforming packs
• Cobot palletising

The complete line can process multiple product formats and is designed for production speeds of up to 400 vials per minute.

By integrating banding directly after tray filling and closing, the line avoids a separate offline sealing or labelling step.

A modular solution for pharmaceutical automation

GTE Engineering designs and builds customised production systems for the pharmaceutical and medical industries.

For GTE, the banding machine therefore needed to fit mechanically and digitally into the complete line.

Bandall’s modular system could be adapted to the tray dimensions, production sequence and available layout. It was integrated with the surrounding equipment and controlled through a Siemens PLC.

The machine can also exchange signals and production data with other parts of the line, allowing banding, printing and verification to operate as one coordinated process.

Fewer materials and fewer process steps

Without banding, securing and identifying the vial trays could require separate packaging components and application stages.

By combining closure and labelling, the system helps simplify the process.

The integrated solution provides:

• Secure closure of folded vial trays
• Clear evidence when the pack has been opened
• Variable data printed directly onto the band
• Automatic verification of printed information
• Fewer separate packaging materials
• Consistent band and print positioning
• Seamless integration into an automated line
• Automatic rejection of non-conforming packs

When reusable plastic trays are used, only the band needs to be replaced after opening, allowing the main packaging component to remain in circulation.

Why banding makes sense for pharma

To GTE, the verdict is clear: banding isn’t just a packaging choice; it’s a smarter way forward.

It simplifies processes, reduces errors, and offers a unique sealing solution. Especially for products like tub-packed vials, where sealing and communication need to work together, banding offers an efficient alternative to traditional stickers or labels.

Even better? When used with reusable trays, the band becomes a low-waste, tamper-evident seal; a powerful combination for pharma companies focused on both sustainability and safety.

Bandall’s technology empowers GTE to serve its clients with even greater precision, intelligence, and adaptability. And the ability to seal and label in a single step is a perfect match for an industry where time, control, and compliance are everything.