The machine was designed to inspect multiple formats of IV bags through a 100% leak detection process based on vacuum decay technology and a patented AI-driven algorithm. Managing six testing stations, multiple loading and unloading areas, and independent movers required precise orchestration of every product movement while maintaining stable and repeatable testing conditions at industrial speed.
Precision for Pharma Quality
Engineering control for pharmaceutical leak detection
Bonfiglioli Engineering develops advanced automation systems for the pharmaceutical industry. Together with Siemens, the company created a high-performance leak detection machine combining Planar Motor technology and SIMATIC automation to ensure quality, flexibility and synchronized operations.
Turning motion complexity into process reliability
Digital foundation for pharmaceutical performance
Autonomous movement, intelligently orchestrated
Planar Motor technology enables each product to travel on an independent XBot mover. Contactless handling and individual routing deliver high precision, flexibility and safe operation throughout the machine.
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Integrated automation and real-time synchronization
SIMATIC S7-1500T and TIA Portal provide the automation backbone of the system. Real-time synchronization ensures precise coordination of movement, testing activities and process control.
Smart traffic management for operational stability
The LPlanarSM software library orchestrates all XBots, turning a dynamic environment into a stable and predictable process. Traffic management prevents interference, ensures continuity and supports repeatable performance.
From autonomous motion to pharmaceutical quality
Managing complexity without compromising accuracy
In pharmaceutical manufacturing, leak detection is a critical quality process where every product must be inspected individually. Bonfiglioli Engineering developed a machine capable of handling multiple product formats and production parameters while ensuring consistent testing conditions and maximum reliability throughout the process.
Combining Planar Motor and SIMATIC technologies
The integration of Planar Motor with the Siemens SIMATIC ecosystem creates a fully coordinated production environment. Autonomous XBot movers deliver unprecedented movement flexibility, while SIMATIC controllers, TIA Portal and LPlanarSM provide centralized orchestration and real-time supervision of the entire system.
Flexibility, continuity and quality assurance
Within a footprint of less than six square meters, the machine manages nine IV bag formats ranging from 50 ml to 1000 ml, multiple production speeds and different leak test sensitivity levels. The result is a compact and scalable solution that reduces setup times, supports production continuity and delivers reliable leak detection performance in demanding pharmaceutical environments.
Thanks to Siemens and Planar Motor, we transformed motion complexity into a fully controllable and repeatable process. Today, we can guarantee reliable leak detection performance while maintaining the flexibility, precision and operational stability required by modern pharmaceutical production