Pharmaceuticals, food and chemicals: strictest requirements and zero defects in the warehouse (Part 2/2).

Welcome to the second part. After highlighting three key challenges and suitable solutions in the first part, we now move on to the next three.

1. transportation of dangerous goods

What applies to hazardous substances in the warehouse also applies to hazardous goods on the road. A small mistake can endanger people, the environment and property. Trucks are only allowed to transport a certain amount of hazardous substances. All hazardous goods require complete classification and documentation. It is important to mark the labels, the delivery bill and the consignment note. During an inspection, it must be clear at first glance what is in the truck and how to handle it.

Classification: Dangerous goods are classified according to ADR for road transport, RID for rail transport and the IMDG Code for maritime transport. Nine hazard classes distinguish between hazard types such as explosive substances, flammable liquids and toxic substances. Each requires its own label, clearly defined risks and specific handling.

Transport document: Nothing travels without it. The transport document must be correct and complete. A safety data sheet (SDS) is also required. This provides information on the properties and handling. This way, everyone knows how the substance behaves at 30 degrees or when tipped over.

The answer: digital dangerous goods management
Our system manages dangerous goods items centrally in the dangerous goods master (also known as dangerous goods dispatch). Each entry contains information such as extinguishing class or labeling requirements. When creating delivery documents and shipping labels, the WMS automatically checks whether dangerous goods are present. If so, it creates all the necessary documents such as transport documents and safety data sheets at the touch of a button. Even limited quantity stickers and pictograms can be printed directly from the WMS.

2. zero-defect picking

Picking errors in the pharmaceutical industry can have serious consequences and lead to incorrect deliveries, delays and quality problems. In the food industry too, incorrect picking can be a disaster. The wrong product, an undeclared allergen, a customer with an allergy. Companies in these sectors are liable for such damage. Costly recalls are the result.

The 1st answer: mobile data capture, EAN no. and put-to-light
A WMS plus MDE device (mobile data capture) replaces paperwork. No scribbling on paper, no pocket-sized stock lists when picking. Instead, there are displays on which every storage location and every picking step is shown and confirmed. Combined with unique EAN numbers that clearly identify products. And if it needs to be even more secure? Then professionals rely on put-to-light. The light shows, for example, which bin on the picking trolley the item belongs in - no mix-ups.

Curious? Together with KBS Industrieelektronik GmbH, we have created a 4-part blog series on pick-by-light. Read it now.

The 2nd answer: Control process in the automated warehouse
It can be even more precise. In the automated warehouse of a pharmaceutical company, the items land directly in the target container, under which there is a scale. A pack of headache tablets - weighing 60 grams - is picked. The system then automatically carries out a reference weighing and checks whether the pack has this weight. If the weight deviates, an error message appears.

The 3rd answer: Inspection function at the packing station
And if you think that's the end of the inspection chain - think again. The last inspection step before dispatch awaits at the packing station: the blind check. Before the parcel goes out, it is scanned, checked and verified again. If something is wrong, an instruction for the next step appears. This control function can be configured flexibly. Mandatory for certain customers, optional for others. And new employees? Picking can be checked in this way during the induction phase.

Conclusion: Zero defects sounds like utopia - but with the right technologies and processes, it is absolutely realistic. It is a goal that is worth achieving.

3. quality and safety standards

Pharmaceuticals, chemicals, food - strict requirements apply in these industries. It's not just about packaging products beautifully or delivering them on time. They must be safe, tested, correctly labeled and fully documented. And this applies from the first production step to the last movement in the warehouse. Sounds time-consuming? It is. And this is where our inspection module comes into play.

The answer: Inspection module for quality assurance
The module does what would be almost impossible to do manually. It defines quality inspection points and random sample inspections, sets target values and tolerances. It also manages blocked stock levels and the tracking of quality deviations. Special inspection steps are linked process-based and put in the correct order. Inspection lots are managed and inspection orders are generated. This ensures that everything remains traceable and documented.

A concrete example: 1,000 packs of headache tablets leave production. They land on a pallet in the incoming goods department. Now the warehouse distribution begins: individual packs move to the small parts warehouse, cartons for pharmacies to the shelving warehouse, excess quantities to the high-bay warehouse. The WMS takes over - but only if the previous QA inspection steps were successful. This includes barcode scanning for traceability and checking the packaging. Everything is automated. Everything remains under control.

Other useful functions for these sensitive sectors.

‍

GMP and GDP - standard in pharmaceutical logistics

In the pharmaceutical industry, the strictest regulations apply to production, storage, packaging and shipping. The processes must be certified in accordance with GMP (Good Manufacturing Practice) and GDP (Good Distribution Practice) guidelines - this is mandatory. GMP and GDP are far more than abbreviations in compliance presentations. They are the guarantee that medicines arrive as they leave the warehouse.

The requirements in production are particularly strict. All software used in supply chain management must be validated, with the exception of the WMS. But even without certification, we support our customers in meeting all GMP and GDP requirements. We place particular emphasis on detailed protocols to ensure test quality.

Temperature control - crucial for product quality

‍Thereare topics where most people initially think: "Well, it'll be fine." Temperature control in the warehouse is definitely not one of them. After all, anyone who works in the chemical or pharmaceutical industry knows that if the temperature isn't right, the product is ruined.

A deviation of just a few degrees in the warehouse is enough. The effect of a medicine can change, a chemical reaction can start unintentionally or a product can spoil. But it takes more than just a cooling system. Intelligent temperature zones are part of a well-thought-out storage strategy.

In our WMS, each product is assigned its own climate class. This classification controls where and how products are stored. In the deep-freeze warehouse at a frosty -20 degrees, in a zone at a moderate -10 degrees or in the so-called ambient warehouse at a temperate 15 to 25 degrees. This is where all products that have no temperature requirements end up - but should not be stored "just anywhere".

Conclusion: Three industries, one principle - quality starts in the warehouse. Whether in the pharmaceutical, food or chemical industry - in the end, success depends on how well things work in the background. Supply chains must be transparent, processes must comply with the law and warehouses must be organized with extreme precision. Mistakes are not up for discussion. Because anything that goes wrong here has consequences for health, the environment and people's trust.

Part 1: Pharmaceuticals, food and chemicals: warehouse management for critical industries (Part 1/2).
Further blog article: Chemical, food and pharmaceutical industries: Seamless transparency and top quality despite batches and best-before dates.