TABLET LINE EQUIPMENT

Transcription

1 TABLET LINE EQUIPMENT CREATING VALUES LEADING INNOVATION LEADING INNOVATION < Comprehensive Solutions for the Pharmaceutical and Nutraceutical Industries Since

2 Contents Overview 3 Pharmaceutical Line - From Concept... to Reality 4-5 TM SortStar Bottle Unscrambler TM Street Fighter Tablet Counters ( SF-100 & SF-200 ) TM SynchroBlock Automatic Desiccant and Cotton Inserter TM TM BeltStar Inline Capper BeltStar Torquer Re-torquer Road Runner Rotary High-Speed Capper TM LabelStar & PharmaStar Bottle Labelers Line Integration Options Line Management & Services 26 Other Services 27

3 World Class Design and Performance Capmatic equipment is well-known for its performance and reliability. Capmatic designs and builds supporting equipment delivering many benefits. Our products are installed globally and have proven to lower long-term operational costs. Capmatic combines innovative application engineering with a keen appreciation of packaging line productivity and efficiency in each of its designs. Capmatic has designed and delivered a variety of equipment for diverse liquid, tablet and powder packaging applications. These systems are designed to improve the overall performance and efficiency of the packaging line. PG OVERVIEW UNSCRAMBLER BOTTLE CLEANER DESICCANT INSERTER TABLET COUNTER COTTON INSERTER ROTARY CAPPER INDUCTION SEALER BUNDLER CARTONER OUTSERTER INLINE LABELER ACCUMULATION CONVEYOR RE-TORQUER World-wide network of authorized partners contributing to strength in consultancy, training, service and maintenance.

4 FROM CONCEPT... BUFFER TABLE SYNCHROBLOCK TM WIREWAY SIDE TRANSFER CONVEYOR Quality Equipment through Innovation is our Primary Objective for your Success!

5 ... TO REALITY. Capmatic manufactures distinctive models of equipment that are essential to build a complete tablet packaging solution. Capmatic can also integrate any piece of its equipment on any existing line. Using monoblock technologies and integrating Capmatic standard equipment, these lines are designed to dramatically downsize the overall required footprint. Generally our solutions will decrease the change over-time, ease the cleaning process and increase the overall efficiency, productivity and profitability. Ideal for the pharmaceutical, nutraceutical and healthcare industries, our new compact tablet line of equipment will exceed your every expectation. PG 05 - PHARMACEUTICAL LINE *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute.

6 SORTSTAR TM The Flexible Bottle Unscrambler without Change Parts Fast, Elegant and Compact... Designed for Reliability TECHNICAL DATA Applications: Speed: Air Consumption / Supply: Power Supply: Machine Dimensions: Round Square Rectangular Bottles Up to 300 BPM* 1 CFM (28 L/min) at 90 psi (6.9 Bar) 220 VAC, 15 Amp, 3 Phases, 60 Hz. W: 2350 mm x D: 2700 mm x H: 1905 mm W: 92 in. x D: 106 in. x H: 75 in.

7 The Capmatic SortStar TM bottle unscrambler is designed to handle a wide range of plastic bottles. Using centrifugal disks and adjustable guides, most bottles can run on this machine without the use of any change parts. All mechanical adjustments are equipped with numeric counters for easy and repeatable change-overs. Optionally most adjustments may also be performed electronically through a user interface allowing for a smoother operating experience. PG 07 - BOTTLE UNSCRAMBLER INTEGRATED BOTTLE CLEANER ASSISTED BY VACUUM SYSTEM Ionized air system to eliminate static from plastic bottles INTEGRATED PRE-FEEDER HOPPER *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

8 STREET FIGHTER TM SF-100 High-Tech Electronic Tablet Counter As shown: Model SF-100 TM Fast, Elegant and Compact... Designed for Reliability Counts: Up to 1,000,000 tablets per hour [from 10 to 1,000 tablets per bottle] TECHNICAL DATA Applications: Tablets Caplets Hard Caps Softgels Speed: Up tp 150 BPM* Estimated at 100 Tablets per Bottle Tablets Diameter: From 2 mm to 20 mm Capsules Size: From 5 to 000 Bottle Diameter: Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.) Bottle Height: Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.) Power Supply: 220 VAC, 20 Amp, 3 Phases, 60 Hz. Air Supply / Consumption: 0 CFM** SF-100 Dimensions: W: 1852 mm x D: 1300 mm x H: 1800 mm W: 73 in. x D: 51 in. x H: 71 in.

9 Countlab StreetFighter TM electronic tablet counter is a technological innovation which combines speed and accuracy in a compact design. The StreetFighter TM (SF series) exceeds cgmp specifications and is designed to meet future regulatory requirements. Countlab visionary design is combined with the most current state-of-the-art computer processing, allowing for an effortless tablet counting experience. The StreetFighter TM electronic tablet counter is designed to handle tablets, caplets, capsules and soft gels. It is capable of handling a wide range of different container shapes and sizes, all while being able to minimize the change-over time through machined parts and simple latching mechanisms. From the vivid solid-state tablet channels and distribution manifold to the programmable bottle feeding system, the StreetFighter TM is the new standard for electronic tablet counters. Visibly recognized for its improvements in Overall Equipment Efficiency (OEE), reduction in change over time, and simplification of daily operations, it is easy to see why the StreetFighter TM is at the top of its category. PG 09 - TABLET COUNTER BOTTLE HANDLING SYSTEM Programmable bottle positioning minimal change parts FAIL SAFE VACUUM REJECT System with mechanical tracking The StreetFighter TM tablet counter also offers a complete operational system that doesn t need any compressed air and has very low maintenance requirements. PRECISION TRAY DESIGN Quick release assembly tablet flow control HIGH EFFICENCY OPTICAL SENSORS Capable of reading tablets as small as 2 mm in diameter *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

10 STREET FIGHTER TM SF-200 High-Tech Electronic Tablet Counter As shown: Model SF-200 TM Fast, Elegant and Compact... Designed for Reliability Counts: Up to 2,000,000 tablets per hour [from 10 to 1,000 tablets per bottle] TECHNICAL DATA Applications: Tablets Caplets Hard Caps Softgels Speed: Up tp 300 BPM* Estimated at 100 Tablets per Bottle Tablets Diameter: From 2 mm to 20 mm Capsules Size: From 5 to 000 Bottle Diameter: Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.) Bottle Height: Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.) Air Supply: 0 CFM** Power Supply: 220 VAC, 20 Amp, 3 Phases, 60 Hz. SF-200 Dimensions: W: 4575 mm x D: 1750 mm x H: 1900 mm W: 180 in. x D: 69 in. x H: 75 in.

11 PG 11 - TABLET COUNTER A fully integrated high speed electronic tablet counter. The Countlab Street Fighter TM SF-200 TM combines two (2) proven SF-100 TM modules with a complete series of motorized conveyor feeding systems connected to a single reject station resulting in a single line component rather than two separate and distinct units. With a unique stainless steel frame and panel control, this new integrated design will facilitate the maintenance and operation of the line, all while ensuring the expected high speed performance. EXAMPLES OF TABLET AND CAPSULE FORMATS. Tablet Round Mini Caplet Capsule Pellet Odd Shape Odd Shape Unique centralized panel control for the dual counter with data acquisition capabillities, meeting 21 CFR part 11 regulations. The SF-200 TM comes standard with a remote monitoring feature and allows communication to any mobile device or centralized monitoring system. *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

12 SYNCHROBLOCK TM Desiccant and Cotton Inserter Fast, Elegant and Compact... Designed for Reliability TECHNICAL DATA Applications: Speed: Bottle Sizes: Bottle Diameter: Bottle Height: Power Supply: Machine Dimensions: Sachet / Canister Desiccant & Cotton Up to 250 BPM* 30 cc to 1500 cc Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.) Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.) 220 VAC, 20 Amp, 3 Phases, 60 Hz. W: 3700 mm x D: 1230 mm x H: 2000 mm W: 146 in. x D: 48 in. x H: 79 in.

13 The SynchroBlock TM desiccant and cotton inserter is capable of handling a wide range of round, square and rectangular bottles with a capacity of up to 1500cc. It can be easily integrated and synchronized with other tablet counting equipment. The SynchroBlock TM is designed for Pharmaceutical and Nutraceutical applications, it can be engineered in numerous configurations to handle sachet desiccant, canister desiccant or cotton and desiccant mixtures. Conceived and built for a tool less change-over system, it also has the capacity of feeding multiple desiccants and inverted U-Shaped insertions. The SynchroBlock TM was engineered and designed with space in mind. This unique equipment solution combines two systems on a unique platform allowing for the smallest footprint possible, without losing speed, accuracy or efficiency. Containers are driven by a servo motor feed screw ensuring perfect synchronicity and allowing for complete tracability of any container. Faulty containers will be rejected via a vacuum star wheel directly onto a single reject station. PG 13 - DESICCANT & COTTON INSERTER SYNCHROBLOCK TM Canister desiccant & cotton inserter CANISTER DESICCANT INSERTER Quick release assembly tablet flow control SERVO DRIVEN BOTTLE HANDLING SYSTEM Programmable bottle positioning minimal change parts POSITIVE TRACKING Fail safe system positive reject confirmation *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

14 BELTSTAR TM Inline Capper Fast, Elegant and Compact... Designed for Reliability TECHNICAL DATA Applications: Speed: Cap Diameter: Bottle Diameter: Bottle Height: Air Supply: Power Supply: Machine Dimensions: Screw Cap Up to 300 BPM* 12 mm to 110 mm From 20 mm to 150 mm From 30 to 350 mm 0 CFM** 220 VAC, 1 Phase, 60 Hz. W: 1116 mm x D: 1153 mm x H: 1673 mm W: 44 in. x D: 46 in. x H: 66 in.

15 Capmatic has redefined the meaning of quality and control with its line of BeltStar TM inline cappers. As part of the company s rollout of tablet packaging equipment, the BeltStar TM staggers its adversaries by providing extensive control and accuracy when handling the bottles and tightening the caps. Without the use of conventional spindles, the BeltStar TM puts itself ahead of the game when it comes to inline capping. The BeltStar TM uses servo driven belt systems to tighten the cap, giving it a considerable contact area ensuring perfect control during the tightening sequence to achieve perfect torque control on every cap. This innovative and superior method of inline capping offers a reduced number of rejects therefore improving the overall efficiency of the line. Lateral container holding belts Conventional Spindle Capper Cap tightening spindle BeltStar TM Solution PG 15 - INLINE CAPPER CAP 188 mm [7 1/2 ] Cap tightening belts Container & cap CAP Lateral container holding belts 7 mm [1/4 ] CAP Container & cap CAP TIGHTENING SPINDLE DEDICATED CAP PICK-UP HEAD Ensures accurate positioning of the bottle with a quick release assembly. Designed as a standard with the capacity to handle a wide range of flat, continuous thread caps, the BeltStar TM offers quality performance and maximum controllability for impeccable proficiency with inline capping. The distinct mechanical design provides accessibility to all mechanical settings visibly to the user. Effortless numeric counters help to deliver precise and quick change-overs for any bottle configuration. MECHANICAL ADJUSTMENTS Executed from the control panel guide with numerical counters for quick change-overs. *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

16 BELTSTAR TM Torquer Re-torquer Fast, Elegant and Compact... Designed for Reliability TECHNICAL DATA Applications: Speed: Cap Diameter: Bottle Diameter: Bottle Height: Air Supply: Power Supply: Machine Dimensions: Screw Cap Up to 300 BPM* 12 mm to 110 mm From 20 mm to 150 mm From 30 to 350 mm 0 CFM** 220 VAC, 1 Phase, 60 Hz. W: 1116 mm x D: 1153 mm x H: 1673 mm W: 44 in. x D: 46 in. x H: 66 in.

17 Enclosed with a high-quality stainless steel surface and a sturdy mechanical system, the servo-driven BeltStar TM machine is our latest innovation. Its technologically advanced system allows for programmable recipe driven change-overs, the capacity to display true torque and the capability of 100% torque verification through the HMI (Human Machine Interface). This unique available option acts as an important source of information and offers the security of knowing the true torque value of every container. Not only does this option display the applied torque but it also rejects any container that is out of spec. With its cgmp design and 21 CFR Part 11 compliance, the BeltStar TM is all you can expect from a torquer / re-torquer. Offering exceptional quality, performance and an extensive variety of options, the BeltStar TM can be considered a fully loaded high-end torquer / re-torquer. PG 17 - TORQUER RE-TORQUER PRESETS ( ACTUAL: B2 C1 ) CAP Ø SET TORQUE 33 mm 20 (in-lbs) TOLERANCE MIN. MAX. ACTUAL TORQUE REJECT STATION START STOP RECIPES ALARMS MAIN MENU LIVE GRAPHICAL APPLIED TORQUE On all caps with the capacity of recording the results. *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

18 ROAD RUNNER Rotary Capper Fast, Elegant and Compact... Designed for Reliability TECHNICAL DATA Applications: Speed: Cap Diameter: Bottle Diameter: Bottle Height: Air Consumption / Supply: Power Supply: Screw R.O.P.P. Press On Caps Up to 600 BPM* 12 mm to 75 mm From 20 mm to 100 mm From 25 mm to 300 mm 1 CFM (28 90 psi (6.9 Bar)** 220 VAC, 15 Amp, 3 Phases, 60 Hz.

19 The Road Runner is a continuous motion rotary plugging / capping system designed for reliability and accurate high speed capping operations. Available in many configurations and options the Road Runner can process from 40 to 600 bottles per minute depending on the number of capping heads selected. The Pick & Place system will ensure perfect placement of any cap at any speed. Depending on the selected options the Road Runner can easily handle child proof, R.O.P.P., aluminum press-on with or without an orientation system (Intellichuck TM ), press or screw pumps and over caps. PICK & PLACE SYSTEM With calibrated clutches for precise torque control PG 19 - ROTARY CAPPER The final torque is engaged by either magnetically calibrated slip clutches or servo motors which are programmable directly from the touch screen control. Quality of the finished product can also be inspected with special sensors or vision systems to ensure that every bottle coming out of the system has a well-positioned cap with the pre-set applied torque. INTELLICHUCK TM For cap orientation & press-on placement POSITIVE REJECT SYSTEM With multiple pneumatic pushers rejecting faulty bottles directly from the outfeed starwheel QUALITY CONTROL VISION SYSTEM To confirm that the pre-set torque has been achieved *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on equipment selection.

20 LABELSTAR Inline Labeler Fast, Elegant and Compact... Designed for Reliability TECHNICAL DATA Applications: Speed: Bottle Sizes: Bottle Diameter: Bottle Height: Air Supply / Consumption: Power Supply: Vials Round Oval Square Rectangular Bottles Up to 300 BPM* 10 mm to 160 mm Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.) Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.) 0 CFM** 220 VAC, 20 Amp, 3 Phases, 60 Hz.

21 The LabelStar family of inline pressure sensitive labeling machines is a flexible and reliable way to handle all types of bottles at speeds of up to 300 BPM*. LabelStar was launched over 20 years ago offering efficient, versatile and easy to handle pressure sensitive labeling systems for the Pharmaceutical Industry. Three platforms were introduced : 1. LabelStar System 1 - For round bottles (Wrap Around) 2. LabelStar System 2 - For any bottle shape (Front & Back, Wrap Around, etc.) 3. LabelStar System 3 - For Top and/or Bottom Label Capmatic developed the LabelStar with the Pharmaceutical Industry always in mind. With that philosophy a stainless steel mono-frame base was developed, in which we integrated all electronic and mechanical components ensuring a smooth, easy to clean finish. PG 21 - INLINE LABELER LABELSTAR SYSTEM 1 For one-sided labels or wrap around labels To ensure flexibility of the equipment it was designed with a multitude of interchangeable modules that can be added or removed without any major modifications to the machine. This gives you advantages and flexibility, covering almost any labeling application you may encounter in the future. All machines can be equipped with a wide variety of options. Any type of coding device can be supplied with the latest in quality verification systems, such as: bar code scanners, vision inspection systems, OCV inspection of the lot #/expiration date, label code verification and label presence sensors. All inspections that fail will result in the defective container being positively rejected. GUARDING SYSTEM Available for increased safety standards The LabelStar family of inline pressure sensitive labeling machines is a flexible and reliable way to handle all types of bottles at speeds of up to 300 BPM* depending on the container and the size of the label. LABELSTAR SYSTEM 2/1 T 5 Panel Label Wiping Station LABELSTAR SYSTEM 1 - HS Inline labeler equiped with redundant Heads for non-stop labeling. *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

22 PHARMASTAR TM Rotary Labeler for Round Bottles Fast, Elegant and Compact... Designed for Reliability TECHNICAL DATA Applications: Round Bottles Speed: Up to 300 BPM* Bottle Diameter: Min. 10 mm (0.3 in.) Max. 85 mm (3.35 in.) Bottle Height: Min. 15 mm (0.6 in.) Max. 250 mm (9.84 in.) Air Supply / Consumption 0 CFM ** Power Supply: 220 VAC, 20 Amp, 3 Phases, 60 Hz. Machine Dimensions: W: 1950 mm x D: 1445 mm x H: 2200 mm W: 77 in. x D: 57 in. x H: 84 in.

23 The PharmaStar TM is a high speed pressure sensitive labeling machine for round bottles using a star wheel system to properly present the bottles to the labeling applicator. Since the bottles are guided inside a star wheel pocket by inline rollers, the system relies on the entire body of the bottle to properly present itself to the peal plate, ensuring perfect placement of the label every time. HIGH CAPACITY CHARGER With splicing table for longer autonomy The PharmaStar TM comes with the most recently developed labeling head from the Capmatic engineering team, the HS 100 & HS 150. This head utilizes a stepper motor capable of handling labels up to 150 mm in height and can dispense labels at speeds of up to 60 meters per minute (196 feet per minute). The PharmaStar automatically keeps track of every faulty container throughout the system ensuring that all flawed containers are discarded onto a motorized accumulation conveyor. PG 23 - ROTARY LABELER FOR ROUND BOTTLES VISION INSPECTION SYSTEM For Quality & Integrity Control FLRS Faulty Label Reconciliation System Besides the standard reject system, the PharmaStar TM can be equipped with Capmatic unique Faulty Label Reconciliation System FLRS. This system is designed to reject any faulty label before it is applied onto the bottle. The faulty label is applied onto an independent backing paper to ensure easy reconciliation of the faulty labels after a production run and to comply with the industry standards of track-and-trace capabilities. This results in minimal product waste as a bottle will no longer be rejected due to a faulty label. For final reporting, a 21 CFR Part 11 data report is also offered as an option. *Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute. **Air supply and consumption depends on selection of optional equipment.

24 LINE INTEGRATION OPTIONS FOR TABLET LINE EQUIPMENT Line equipment options and integration are important on any project. They ensure efficiency of the line and a quicker return on investment. Capmatic is a solution provider and a detailed analysis of the project is the key factor to ensure that the most appropriate equipment is delivered. Line Integration Options: Metal Detector Checkweigher Desiccant and Cotton Inserter Induction Sealer Neck and Body Bander Outsert Applicator Coding Device Cartoner Bundler Case Packer On occasion, customer requirements demand a need for peripheral equipment that may not always be part of Capmatic manufacturing program or expertise. In these cases we are always open to recommand specific options or third party machines, based on our experience in the industry, or to incorporate machines selected by our customers. We will propose options that will enhance the production of the line and lead to higher performance and reduced down time.

25 21 CFR PART 11 COMPLIANCE BUFFER TABLE Bi-flow accumulation table custom-built with a variety of options REJECT FALLEN BOTTLE DIVERTER PG 25 - FEATURES & BENEFITS SWING OUT CONVEYOR WIREWAY & SIDE TRANSFER CAPMATIC FEATURES AND BENEFITS: 50 year of experience Modular design cgmp compliance Slight or no dependency of external air source Simple and repeatable change-overs without the use of any tools Programmable recipes for different products and components Low maintenance Equipment fully enclosed with interlocked safety doors Allen-Bradley P.L.C. with Ethernet connectivity and touchscreen control 21 CFR Part 11 Compliance Batch process control reporting Knowledgeable staff on hand Long-time validation experience and support staff Single point for FAT Worldwide network

26 LINE MANAGEMENT DATA ACQUISITION & REMOTE MONITORING and Services Line Monitoring Systems allow you to effectively follow and record the efficiency of the operation for each piece of equipment on the packaging line. Machine downtime can be identified through the use of an integrated system that will report real time OEE (Overall Equipment Efficiency) and downtime events for review and further analysis in order to improve the line operation. Manual collection of data and preparation of reports generally does not provide the same degree of accuracy and is not as readily available to bring Line Monitoring to a world class standard. Monitoring is generally accomplished through the use of terminals connected to each line component collecting selected data. This provides access for operators to view the information collected and input details as required. In most cases these terminals can be linked via Ethernet to a central PC. The PC displays the status of all machines at a single glance. Access to individual operations of the linked machines and OEE is also available for display and can be continually updated. These systems continuously monitor all machines and accurately record downtime. They can also be used to generate reports that include OEE (Overall Equipment Efficiency), total production and rejects. Data Analysis can be matched to any time period, machine, operator and product depending on the information requested. This approach helps to free up personnel from the task of data collection and processing, it also eliminates the risk of inaccurate data entry. PLC Drives HMI DATA ACQUISITION & REMOTE MONITORING

27 In any production line, Capmatic can also integrate devices and software for Track & Trace regulations which will soon become mandatory in many states. Line monitoring with data acquisition capabilities meeting the 21 CFR Part 11, IQ / OQ / DQ / FDS regulations are also readily available. As part of the customer support service, Capmatic established the validation department to assist customers with efficiency and promptness; qualifying equipment with documentary evidence in a format that compliments the existing qualified documentation. PG 27 - OTHER SERVICES The quality and reliability of our equipment, along with our excellent service, engineering departments and 75,000 square foot facility in Montreal have made Countlab and Capmatic a leader in the packaging industry. VALIDATION PROTOCOL DATA REPORTING TRACK AND TRACE

28 Since World Wide Services 12180, Albert-Hudon Montreal (Quebec) Canada H1G 3K7 T: (514) F: (514) labelstar.com capmatic.com countlab.com steelheart.ca