Kohlpharma, a leading pharmaceutical importer based in Merzig, Saarland, Germany, has recently added 22 HERMA type 452C S top labeling machines to its operations. The company places a high priority on flexible and precise labeling for its pharmaceutical products, requiring over 100 HERMA label applicators to meet these needs.
As the market leader in Germany, Kohlpharma continues to grow as a parallel importer of pharmaceuticals. The company takes advantage of the varying prices of multinational pharmaceutical products across different EU countries. By importing proprietary drugs from well-known manufacturers, Kohlpharma is able to offer medicines at an average of 10 percent cheaper than in local markets, benefiting both patients and health insurance companies.
In Germany, pharmacies are obligated to offer low-cost imported drugs, contributing to overall savings. However, the business often involves handling small quantities of medications. Kohlpharma processes around 200 pallets of goods per week, but the medications typically arrive in small batches, sometimes as few as one item for expensive pharmaceuticals. Since the original packaging must often remain intact for branding purposes, each package requires at least one German-language label. In some cases, up to five or more labels are needed for primary and secondary packaging. On average, Kohlpharma applies around 200,000 labels per day, produced in-house using laser die-cutting.
“Due to the small batch sizes, our label applicators need to be set up quickly, and consistent quality is essential,” explains Wolfgang Barth, Group Manager of Production Technology at Kohlpharma. “HERMA labeling machines are perfectly suited for this, thanks to their design and operating concept.”
Flexibility and Precision are Key
In addition to flexibility, precision is crucial for Kohlpharma’s labeling processes. Some manufacturers require exact specifications, such as not reprinting certain logos or text, and the labels must fit with millimeter accuracy.
“Our labels often contain precise cut-outs, which must align perfectly,” Barth explains, emphasizing the challenge. “Kohlpharma likely has the most experience in managing such a broad range of packaging and small batch sizes while maintaining efficient labeling processes.”
The modular design of the HERMA 500 applicators allows for great flexibility, which is further enhanced by custom tuning based on Kohlpharma’s extensive experience working with these machines.
“Attention to detail is extremely important to us,” Barth says. “The list of small details we consider continues to grow, but HERMA has been able to accommodate all of our needs perfectly.”
Ensuring Accuracy in Label Alignment
Another area where precision is crucial is when applying new wrap-around labels to small bottles.
“We cannot remove the original label, so the new one must be positioned perfectly to cover it, ensuring the viewing window remains clear. If the original logo needs to be visible through a cut-out in the new label, the alignment must be flawless,” Barth adds, highlighting the complexity of the task.
Kohlpharma recently surpassed one billion Euros in turnover, but the competition in the pharmaceutical import sector remains intense. Barth and his team are always striving to improve efficiency, even in the smallest aspects of their operations.
“My goal is to work more with standardized format parts in the future,” Barth says. “While this is challenging due to the small order sizes and rapidly changing product range, I’m confident that we’ll continue to find solutions with HERMA.”
