Gerresheimer Expands Technical Competence Center in Wackersdorf 

Gerresheimer is dedicating even more space to small batch production. It has expanded the capacity of its small-batch production (SBP) area in Wackersdorf by removing a section of the high-bay warehouse and converting it to a manufacturing space. The new Small Batch Production Sampling Area Wackersdorf measures 700 square meters and will be used to manufacture pre-series parts for assembly systems. The expansion is a further display of Gerresheimer’s far-reaching industrialization expertise in the manufacture of containment solutions, drug delivery systems, and medical devices.

Gerresheimer has taken the next strategic step in its future by expanding its Technical Competence Center and SBP facilities at the Wackersdorf location for the third time in just five years. The new 700 square meters Small Batch Production Sampling Area is where pre-series parts — samples used to set up manufacturing systems — can be produced at series quality. An area that previously housed a high-bay warehouse has been converted and equipped to meet the latest production standards.

“This is our response to the changing project environment, which involves a growing number of large-scale industrialization projects with many different tools and large machinery,” said Holger Heining, Head of Small Batch Production Gerresheimer Regensburg GmbH, Wackersdorf. “For their high-volume assembly systems, industrialization projects require a large quantity of pre-series parts in documented series quality at an early stage of the project cycle. With our new Small Batch Production Sampling Area, we can now meet these demands and handle the rising number of large-scale industrialization projects in the best possible manner.”

Unlike development projects, industrialization projects require automatic tool handling for high-volume manufacturing. The new area reflects these new parameters, featuring 10 injection molding machines with a clamping force of 175 to 420 metric tons.

Small-batch production at Wackersdorf in the Upper Palatinate region of Germany started up exactly ten years ago. In 2013, the first injection molding machine and automation solutions at the location were installed in a small room. The setup proved to be resounding success, kicking off a series of expansions to the facility. The first parts of the warehouse were converted to clean room production areas for injection molding and the assembly of plastic products in 2015. Three years later, in 2018, Gerresheimer invested an eight-digit figure in the construction of new grade C and grade D clean rooms and expanding its small-batch expertise to the glass sector.

In 2020 and 2021, the company made another eight-digit investment at the Wackersdorf location, this time focusing on plastics. By expanding the production area to 2,750 square meters in total, Gerresheimer responded to the growing number of projects that require smaller batches or a small quantity of pre-series products for development, approval, and industrialization purposes. The investment involved the construction of new office space but predominantly focused on creating ISO class 7 and 8 clean room facilities.

Wackersdorf now has 2,170 square meters of class 7 and 8 clean room production space, a 220 square-meter controlled area, and a 360 square-meter clean room for pharmaceutical glass products that meets GMP class C and D requirements.

Gerresheimer is continuing on its growth trajectory, and the Wackersdorf location is no exception. That’s why the highly motivated, dynamic team is looking for new faces in the shape of experienced experts, young talents, and trainees who are keen to use state-of-the-art approaches, systems, and methods to contribute to the success of the projects and of the company as a whole. Gerresheimer intends to create over 40 new jobs in Wackersdorf over the coming months.

With a team of around 520 in Wackersdorf and a further 650 employees just 30 km away in Pfreimd, Gerresheimer is one of the larger employers in the region. Overall, the MDAX-listed company employs around 11,000 people worldwide.

 Gerresheimer is the innovative system and solution provider and global partner for the pharma and biotech industry. The company offers a comprehensive portfolio of pharmaceutical containment solutions, drug delivery systems and medical devices as well as solutions for the health and cosmetics industry. The product range includes digital solutions for therapy support, medication pumps, syringes, pens, auto-injectors and inhalers as well as vials, ampoules, tablet containers, dropper bottles, other bottles and more. Gerresheimer ensures the safe delivery and administration of drugs to the patient. With 36 production sites in 16 countries in Europe, America and Asia, Gerresheimer has a global presence and produces locally for the regional markets. With over 11,000 employees, the company generated revenues of around €1.82bn in 2022. Gerresheimer AG is listed in the MDAX on the Frankfurt Stock Exchange (ISIN: DE000A0LD6E6). For more information, visit www.gerresheimer.com.