Rotzinger unveils VarioFill  for OTC product packaging

GERMANY – Rotzinger PharmaPack has introduced VarioFill, a modular filling and capping platform designed for over-the-counter (OTC) pharmaceuticals, cosmetics, personal care, and nutraceutical products. 

The platform streamlines production by handling both liquid and solid products, such as eye drops, cough syrups, creams, serums, tablets, and capsules, on a single machine. 

According to Michael Gensheimer, Product Manager at Rotzinger PharmaPack, “VarioFill allows manufacturers to process diverse products and closures on one platform, eliminating the need for multiple machines.”

Space-saving modular design

VarioFill’s compact footprint reduces space requirements by over 50% compared to traditional production lines. 

Its modular design enables quick reconfiguration with exchangeable modules, minimizing investment costs. 

“All you need to do is reconfigure the platform with the appropriate modules, and it’s ready for new requirements,” Gensheimer explained. 

This flexibility is ideal for manufacturers and contract fillers facing frequent product changes, allowing seamless adaptation to various container shapes, packaging materials, and closure types like snap-on, screw, pump, or crimp.

Advanced automation and quality control

The platform incorporates gentle container handling using magnetically driven grippers, eliminating the need for guiding parts like pucks. 

Containers, such as glass or plastic bottles, are fed via a belt system or Rotzinger’s pickFeeder with delta robots for sorting.

A 100% in-process control (IPC) system weighs containers before and after filling, ensuring precision. 

Filling is managed by sealless rotary piston pumps or counters, depending on the product.

A fully automated cleaning-in-place (CIP) system maintains hygiene by moving product-contact parts to a cleaning position and back. 

In a statement, Gensheimer noted that the platform’s design allows customers to “configure their solution to suit production needs and expand it flexibly.”

Recent industry updates highlight similar innovations. At PACK EXPO International 2024, groninger showcased its flexcare 101, a filling and closing line for OTC products like eye drops, processing up to 120 bottles per minute with enhanced hygiene features. 

This indicates a growing trend toward compact, versatile systems in pharmaceutical packaging.

Customer response to VarioFill has been strong, with two lines sold before the official launch. The first is set to begin production soon, with more expected to follow. 

The platform’s ability to consolidate processes while maintaining flexibility positions it as a practical solution for diverse production environments, meeting the evolving demands of the OTC market.