Fanuc Roboshots deliver zero unplanned downtime

Thanks to their proven repeatability and reliability, Fanuc’s Roboshot injection moulding machines have become a cornerstone of Sovrin Medical Plastics business strategy. Over the past two decades, the Slough-based contract manufacturer has built up a fleet of 34 Roboshots dedicated to producing medical devices and components.

Remarkably, Sovrin cannot recall the last time an unplanned breakdown occurred — a testament to the Roboshots’ durability. This is especially impressive given that the moulding cells operate 24/7 for 50 weeks a year, with some of the oldest units having completed over 40 million cycles.

James Joiner, managing director of Sovrin Medical Plastics, said: “We simply don’t experience downtime with the Roboshot machines. Their reliability and repeatability have been so consistent that, after 20 years, we cannot even recall the last time we had a breakdown. At this point, we take their performance for granted – reliability is just a given.”

Pictured left: Fanuc Roboshots installed at Sovrin Medical Plastics

Engineering excellence underpins this performance. Sovrin’s engineering director Adrian Hill attributes the company’s enviable track record to Fanuc’s vertically integrated manufacturing approach and a rigorous programme of planned maintenance.

He said: “Fanuc is unique in that it develops and manufactures its own OEM parts and has done for many years – a vertically integrated approach that is a major contributor to the high uptime and long lifespan that are the hallmarks of its machines. When we buy a Fanuc model, we know exactly what we are getting — from one machine to another, the only thing that changes is the tonnage of the machines. The motors and drives are the same and if you open the control cabinets, you will find Fanuc components.”

Mr Joiner added: “Being able to rely on proven engineering is essential to our business because it mitigates risk, something that is crucial to us as a contract manufacturer. The fact we can say we are a Fanuc user is also a key selling point for potential customers. Any procurement people who have done their homework will know that Fanuc is the golden standard in our industry.”

Sovrin works closely with Fanuc’s servicing department to ensure optimum performance from its machines. Every unit is serviced annually, and during these visits, Fanuc engineers highlight any maintenance that is needed. Mr Hill continued: “Much of their machines’ reliability comes down to this methodical approach.”

Enviable track record
Sovrin’s journey with Fanuc began in 2005, when it acquired its first five Roboshot machines to produce dry powder inhalers as part of a global provisioning response to the bird flu pandemic. This marked the start of a 10-year transition from hydraulic to clean, energy-efficient all-electric technology. In 2016, Sovrin opened a ‘state of the art’ manufacturing facility dedicated to medical device production.

Pictured right: The moulding cells operate 24/7 for 50 weeks of the year

Equipped with ISO Class 7 cleanrooms and customer-dedicated manufacturing cells, the centre was populated exclusively with 31 all-electric Fanuc Roboshot machines. Mr Hill recalled: “When we moved into the new facility, we didn’t bring any of the old hydraulic machines with us. By then we were completely converted to the repeatability, reliability and cleanliness of all-electric.”

Sovrin’s investment in Fanuc’s all-electric technology continues today. Its latest acquisitions — two S250iA machines — are dedicated to the ophthalmic sector. Mr Joiner explained: “We have been supplying blisters to one of the world’s leading contact lens manufacturers for over 15 years, and in 2023, we invested in two new moulding cells in response to increased demand.”

The high-volume, just-in-time manufacturing strategy required for this product demanded a fast-cycling injection moulding solution, and the S250iA Roboshot machines delivered. Mr Hill concluded: “They are producing a 32-impression product on a 5.5sec cycle, delivering precisely the repeatability and reliability that we have come to expect from Fanuc.”