The Medical Plastic Systems business (MPS; Regensburg / Germany) of Gerresheimer Group (Düsseldorf / Germany; www.gerresheimer.com) plans to make significant investments in the coming years to meet the demands of its diagnostic, pharmaceutical and medical technology customers. Taking account of the constantly changing market requirements, the manufacturer of inhalers, pen systems, lancing devices, laboratory disposables and quick tests will extend its vertical and horizontal value chain and considerably expand its global production capacities.

As COO and CTO Manfred Baumann and CPO Oliver Burgel explained at a recent press conference in Wackersdorf / Germany, the life expectancy of products for pharmaceuticals should be about 10 years, while diagnostic products should last for around five years. In the latter case, the life expectancy is becoming shorter all the time. The colour and design of diagnostic devices are increasingly being adapted not only to the preferences of regional target groups, but also to changing patient expectations in terms of their mode of operation and to new legal requirements.

By 2014, the company intends to significantly expand production capacity at its sites in Pfreimd / Germany, Horšovský Týn (Czech Republic), Küssnacht / Switzerland, Indaiatuba / Brazil, Dongguan City / China and Peachtree City, Georgia / USA. The production area is to be extended by around 30% to 78,000 m², the clean room areas (classes 7, 8 and 9 to DIN EN ISO 14644) by 55% to about 45,000 m², and the number of injection moulding machines by 40% to around 400. The assembly capacity will more than double to around 120 stations.

Gerresheimer MPS’ main production hub is in Pfreimd / Germany, where a two-storey production hall and a new fully automatic high-bay warehouse with room for 2,400 pallets in clean room category 8 are currently under construction. By 2014, the production area will be extended by 5,600 m² to 27,800 m². In addition, 40 new injection moulding machines will be installed, bringing the total to 110. There will also be 30 new assembly lines, making 106 in all. The investment for this alone will be EUR 33m.

MPS will also drive expansion in Horšovský Týn. By 2014, the production area will double to 27,000 m² and the number of injection moulding machines will rise to 95. The plans for Küssnacht in Switzerland are comparatively modest, with the number of injection moulding machines growing from 27 to 42 and the number of assembly stations rising to 15 – see Plasteurope.com of 22.10.2012. The Peachtree City site will also be expanded in the medium term, while the one in Dongguan City will be extended by 2014 to give it a total production area of 1,800 m². The number of injection moulding machines will rise from 15 to 20 and three semi-automatic as well as three manual assembly lines will be installed. At the Brazilian site of Indaiatuba, where Gerresheimer produces for a single customer, the production area will be increased in 2014 to 3,700 m², while 25 injection moulding machines, five laser printing units and two offset printing units will also be installed.

In parallel with the capacity expansion measures, Gerresheimer MPS aims to strengthen its position as a technology leader. After setting up the Technical Competence Centres (TCC) in Wackersdorf in 2006 and Peachtree City in 2009, a TCC will be opened next year in Dongguan City for projects for its Asian customers. In its TCCs, Gerresheimer simulates the entire product-creating process – from product design to production engineering, including all the processes, tools, assembly stations and other equipment needed for series production. The longer value chain constitutes an all-in solution covering not only the injection moulding activities but also assembly, packaging and finishing as well as "pharmaceutical manufacturing". The all-in solution means Gerresheimer will also be setting up a pharmaceutical assembly and packaging area in Pfreimd.

Gerresheimer MPS is derived from Wilden, which the group acquired in 2007. The business is now the fastest-growing unit within the company. With a workforce of more than 1,800, MPS posted sales of around EUR 240m last year.