How Dr Reddy's achieved global pharma traceability milestone

Dr Reddy's Laboratories (DRL), a leading Indian pharmaceutical manufacturer serving highly regulated markets including the US and Europe, has successfully strengthened its compliance and data integrity framework by partnering with Wimco by Stelda. The collaboration focused on retrofitting DRL’s existing Wimco GAN 120 tube-filling machine with advanced digital verification systems, setting a new benchmark for pharma traceability and 21 CFR readiness.

The upgrade was a direct response to the stringent demands of international markets, where absolute precision in packaging and labelling is non-negotiable. DRL's primary challenge was eliminating the risk of product mismatch and enhancing traceability beyond the capabilities of its legacy iMark (black strip) registration system, which offered no data recording for audit purposes. Maintaining production efficiency while introducing a sophisticated, error-proof system was also a key requirement.

The Wimco by Stelda’s engineering and automation team transformed the GAN 120 machine by integrating a smart barcode registration system to replace the traditional iMark.

As per Sunil Chaudhari of the Wimco-Stelda Group, "Every tube is now processed with a unique product barcode that is scanned and verified at the filling station." Chaudhari added, "This system provides real-time, automated verification, ensuring that only the correct product is processed and linked to the corresponding batch data. This move from a mechanical to a data-driven platform eliminates the risk of mix-ups during multi-SKU runs and delivers audit-ready digital documentation."

Building on the success of the barcode system, the two companies are currently implementing optical character recognition (OCR) technology. Once complete, the OCR system will automatically capture and verify batch codes and expiry dates printed on the tube seal. This two-pronged validation—barcode for product identity and OCR for printed data—will achieve end-to-end digital traceability.

Furthermore, Wimco by Stelda ensured that the machine's design for filling pumps, nozzles, and tubing systems supported rapid disassembly and autoclave sterilisation. This attention to detail minimises downtime during product changeovers while adhering to DRL's strict cross-contamination and hygiene protocols.

The successful implementation of the barcode registration system has delivered immediate, measurable benefits for DRL:

The collaboration demonstrates that targeted, cost-effective automation upgrades can successfully transform existing equipment into digitally traceable, compliance-ready assets without requiring a complete line replacement. 

Chaudhari signed off by stating, "This project solidifies Wimco by Stelda's position as a critical partner in the pharmaceutical industry, helping clients achieve global regulatory confidence and operational excellence.