Case Study: Executing Complex Pharma Automation Through Build-to-Print Manufacturing

This case study highlights DT Engineering’s role delivering automated engineering for the pharmaceutical industry by building a highly specialized Single Dose Automation System. Designed for blister card medication fulfillment, the system was built to the customer’s exact design specifications, showcasing our capacity to handle complex pharmaceutical manufacturing projects and deliver high-quality, customized solutions

 
 
 

The Challenge: Scalable, Accurate, and Compliant

The customer’s challenge was developing a highly efficient and automated single-dose blister card fulfillment system.

The machine needed to:

  • Be compatible with existing pharmacy management systems.

  • Handle a high throughput of up to ten cards per minute.

  • Ensure accuracy in labeling, sealing, and barcode verification.

  • Be scalable for growing pharmaceutical production demands.

  • Meet stringent pharmaceutical industry regulatory and compliance standards.

  • Be constructed, assembled, tested, and validated at a single location–a one-stop solution.

Their project required a trusted pharmacy partner with significant expertise in BTP manufacturing and system integration, capable of bringing complex designs to life while ensuring top-tier performance and pharmaceutical regulatory compliance.

 
 
 

Are you facing the same challenges?

 
 
 

Turning Vision into Reality in Pharmaceutical Automation

In today’s fast-paced and highly regulated pharmaceutical industry, the demand for efficient, reliable, and scalable automation solutions is growing. These industries require partners who can bring designs to life with precision and efficiency. DT Engineering’s proven expertise in pharmaceutical manufacturing brings conception to reality with Build-to-Print (BTP) delivery, empowering clients in the pharmaceutical sector to automate critical processes, ensuring operational excellence and compliance.

Maximizing Value Through Engineering Innovation

As part of this Build-to-Print project, DT Engineering applied value-driven and smart automated engineering strategies to:

  • Meet aggressive delivery goals and reduce costs without compromising quality

  • Accelerated lead times by redesigning sub-systems for manufacturability and ease of assembly

  • Optimized costs through part consolidation, material substitution, and strategic sourcing

  • Managed component obsolescence proactively—replacing outdated parts to ensure long-term reliability and supply chain stability

 
 

From Blueprint to Blister Pack: DT Engineering’s Seamless Execution

Our role in this project centered on executing the customer’s design with precision and expertise, handling every phase of the production lifecycle:

  • Material sourcing and pharmaceutical manufacturing

  • Quality assurance and final system validation in the pharmaceutical industry

  • Long-term maintenance support and service

Our Build-to-Print Capabilities

 
 

Build-to-print manufacturing is a production approach where DT Engineering creates a product exactly according to a customer's detailed design specifications, drawings, and documentation. In this pharmaceutical production model, DT Engineering doesn't design the system—we simply build it "to print."

 

Comprehensive Manufacturing and Assembly

We expertly manage all aspects of production, from raw material selection to final assembly, ensuring seamless execution of print-ready designs.

Quality Assurance and Testing

Our Quality Management System processes are in place to ensure every build meets stringent performance, durability, and compliance standards in the pharmaceutical industry.

Scalable Production Capabilities

With proactive coordination, we minimize delays and keep build-to-print projects on schedule without compromising quality in pharmaceutical production.

Comprehensive In-House Support

We take over full control of the the project’s lifecycle, from engineering, purchasing, and project management.

From Plans to Production: DT Engineering’s Lasting Impact

By delivering a high-performance single-dose automation system tailored to the customer’s specifications, DT Engineering proved its strength as a reliable and skilled manufacturing partner. The successful execution of this automated engineering project:

  • Accelerated time-to-market

  • Improved patient safety

  • Streamlined regulatory compliance

  • Reduced cost of ownership

This project is a testament to DT Engineering’s ability to:

  • Bring customer designs to life with exceptional quality.

  • Execute complex automation projects that meet stringent regulatory standards.

  • Provide end-to-end Build-to-Print services, from design validation to manufacturing and testing.

 
 

Looking for a trusted Build-to-Print manufacturing partner?

Whether you're bringing a complex design to life or scaling production of an established system, DT Engineering has the expertise, infrastructure, and dedication to deliver with precision.

Let’s talk about how we can support your next pharmaceutical industry initiative—from concept validation to full-scale production. Fill out the form, and a member of our team will be in touch shortly.

dtengineering.com

1107 Springfield Rd.,
Lebanon, MO 65536

(417)532-2141