IWK expands cartoning capabilities for autoinjector pens

IWK Packaging Systems is expanding the capabilities of its CH 4 Horizontal Cartoner to accommodate autoinjector pens, responding to growing demand for flexible secondary packaging systems across pharmaceutical and medical-device manufacturing.

The company will demonstrate the expanded configuration at Pack Expo 2026 in Chicago from 18 to 21 October. During the event, the machine will package a Ypsomed injection pen in a paper tray loaded by an Omron robot before inserting the device into a folding carton.

System reaches speeds of 120 cartons per minute

The CH 4 can operate continuously or intermittently and achieve speeds of up to 120 cartons per minute, depending on carton dimensions and the inserts required for each application.

The machine accommodates cartons ranging from 50 to 230 mm in length, 15 to 160 mm in width and 15 to 100 mm in height, giving pharmaceutical manufacturers flexibility across different products and secondary packaging specifications.

Servo technology supports precise handling

Servo motors power the system and allow packaging movements to be precisely controlled throughout the cartoning process. IWK has also incorporated timing belts and four-level positioning to reduce the risk of scratching or damaging sensitive medical devices.

Gentle handling is particularly important for autoinjectors and pen devices, where cosmetic damage or mechanical stress can affect product quality, consumer perception and potentially the functionality of the delivery system.

Automation integrates product and tray loading

At Pack Expo, the CH 4 demonstration will combine automated robotic loading with paper-based secondary packaging. The tray and folding carton are supplied by Kartonveredelung Knapp, while an Omron robot will position the injection pen inside the tray.

This integrated approach demonstrates how robotics, cartoning and material handling can be combined to reduce manual operations while maintaining high throughput and repeatability on pharmaceutical packaging lines.

Flexible equipment responds to changing drug formats

Demand for autoinjectors, injection pens and other patient-administered drug delivery devices continues to increase as pharmaceutical treatments become more sophisticated and therapies move towards greater convenience outside clinical environments.

This trend creates new requirements for secondary packaging machinery capable of handling different device dimensions, inserts, trays and carton formats without extensive equipment changes.

Compact footprint remains a design priority

IWK positions the CH 4 as a multifunctional end-of-line solution for pharmaceutical brand owners and contract manufacturers. The system is designed to deliver high output while maintaining a relatively compact production footprint and compliance with current Good Manufacturing Practice requirements.

Space efficiency is becoming increasingly important as pharmaceutical manufacturers introduce new assembly and packaging equipment into existing facilities while expanding capacity for injectable drug formats.

Autoinjector growth drives packaging investment

Investment in autoinjector and pen packaging capacity has increased as biologics, weight-management therapies and other injectable treatments expand. Packaging systems must protect increasingly valuable devices while supporting traceability, automated inspection and efficient high-volume production.

By extending the CH 4 platform to autoinjector pens, IWK is positioning the machine to serve this growing segment while giving manufacturers greater flexibility to switch between different pharmaceutical and medical-device packaging applications.