Blister machine UPS 5 Focus on product diversity

Transcription

1 Blister machine UPS 5 Focus on product diversity

2

3 The fast and efficient translation of customer requirements into world-class packaging machines and solutions is one of Uhlmann s guiding principles. A central part of this process is evolution, the optimization of machines and their consistent development into a new class of machines. This is the case with the Blister machine UPS 5. The success story of this machine for diverse applications in pharmaceutical production began in 1977 with the UPS 1. At every subsequent development stage, Uhlmann engineers supplemented proven features with innovative components and state-of-the-art technology. Accordingly, the UPS 5 combines the advantages of its predecessor model with many additional attributes. Blister machine UPS 5 Focus on product diversity

4 The philosophy behind the Blister machine UPS 5 Building on the success of the UPS 4 and its outstanding flexibility in blister packaging technology, the UPS 5 expands that potential by combining established and proven features with even greater benefits in the context of state-of-the-art technology, ease of operation, maintenance, and flexibility.

5 The GMP-compliant Blister machine UPS 5 sets standards in flexible, productive pharmaceutical packaging processes. The modular frame allows variable configurations and machine upgrades at all times. Each station forms an individual unit and is mounted separately on the machine frame. Enclosure of all the stations protects them from dirt or crosscontamination, and reduces sound levels. The large format area and a forming depth of up to 40 mm enable the UPS 5 to package liquid dose products such as ampoules, cartridges, vials and syringes in addition to solid dose products. The format area of 226 x 284 mm extendable to 272 x 284 mm is particularly suitable for largesized blisters as well as calendar or laboratory packs. The maximum output of the UPS 5 is 400 blisters per minute. A wide selection of feeders can be integrated to ensure flexible application for diverse products. The UPS 5 is also flexible in the context of tools. Tools from the preceding Blister machine UPS 4 can be used on the UPS

6 The technology of the Blister machine UPS 5 The UPS 5 is ideal for the productive packaging of solid and liquid dose products. Its modular concept and ease of operation meet the current demand for customized, flexible processes. Forming material reel support: diverse options Heating station: automatic heat control The UPS 5 can be fitted with forming material reels up to 800 mm in diameter, which allow extended operation. Changing of the reel is made easier by electro-pneumatic lowering of the reel support, and ergonomic positioning of the cutting and splicing table. The forming material reel support can be connected from the left, the front, or from behind, depending on the available space or the desired feeding position. Furthermore, a forming material buffer means that the forming material reel can be changed during ongoing production. Three adjustable heating zones on the heating plates ensure an optimum forming process and extend the heating area over three indexes. Sensors automatically monitor and digitally control the temperature of the forming material so that temperature differences on the surface are restricted to ± 2%. The heating plates can be removed quickly and easily for maintenance purposes. Forming material reel support Heating and forming station

7 Forming station: universal, efficient The universal forming station processes all common types of forming material with consistent reliability. Features include a four-column lifter unit that ensures even distribution of the station closing pressure of up to 80 kn. As the forming station, like most of the UPS 5 stations, is driven by a patented cam-toggle lever system, the main shaft of the machine is not subjected to deflection loads. The closing pressure is absorbed by the station itself. The UPS 5 allows forming depths of 10 mm to 40 mm, which makes it the ideal machine for the packaging of liquid dose products, tropical blisters, and Al/Al blisters. Plug assist dies are used for larger forming depths and certain wall thickness distributions, e.g. in the case of PVDC or PVC/Aclar laminates. Heated plug assist dies are used for PP materials. These options ensure excellent results with all forming materials

8 The technology of the Blister machine UPS 5 Feeders: efficient and gentle product handling A wide selection of feeders can be used with the UPS 5 both for liquid and solid dose products. SyPro and LiPro are the feeding systems for liquid dose products. SyPro short for Syringe Product operates with a swivel-arm robot for the gentle feeding of fragile glass or plastic syringes. LiPro short for Liquid Product likewise uses a robot arm for the dedicated placement of ampoules, cartridges, vials and bottles. The feeding systems can be installed on the front or rear side of the UPS 5. In the case of upstream machines, e.g. an ampoule filling machine, direct, seamless linking is guaranteed. Feeders are available for the handling of every shape, size and type of solid dose products. SimTap feeders with dedicated product placement are compatible with both continuous and intermittent modes of operation, and are suitable for high-speed production. The universal feeder dispenses with specific format parts for each product shape. The fill box feeder is SyPro feeding system

9 Lid material reel support and unwind: minimum tolerances ideal for multiphase blisters, and the linear feeder handles products of complex shape, ones with noticeable differences in tolerance range, and products susceptible to shingling. No matter whether solid or liquid dose products, the fill section of the UPS 5 can be extended for the simultaneous operation of more feeders or the addition of manual feeding workplaces. The lid material reel can be positioned at the front or on the rear side of the UPS 5. The lid material elongation function ensures high-precision print mark control with tolerances of just ± 0.2 mm. The print mark registration for paper lid materials is driven by a servo-regulated index. Sealing and embossing: integrated and reliable Intelligent technical solutions for sealing and embossing ensure maximum process reliability. The four-column platen sealing station guarantees even distribution of the sealing pressure of up to 80 kn, and includes an overload function. If the machine is stopped, the sealing station opens automatically to protect the products from the sealing heat. When packaging heat-sensitive products, the automatic insertion of an air-cooled heat shield between the upper sealing plate and the product during a machine stop is possible. Tool-free format changeovers are fast and easy. The sealing station of the UPS 5 integrates the embossing function and thus saves space and costs. Sealing and cooling station 08 09

10 The technology of the Blister machine UPS 5 Perforating: utmost precision Punching: accurate and quiet The perforating station operates with utmost precision. Its four-column technology guarantees even pressure distribution for optimum results. Furthermore, the individually fixed perforating knives are easy to replace. Compared to the UPS 4 predecessor machine, removal of the perforating tools is much easier and quicker. This is beneficial for servicing and maintenance purposes. The high-precision tools in the cam controlled punching station allow very accurate blister punching. When processing very long material lengths, an optional, floating, laser-controlled punch can be used to compensate shrinkage. The new guarding concept noticeably reduces the sound level (69 db [A]). Tool-free format changeovers are carried out from the front of the machine. Perforating station and index Punching station

11 Blister transfer Discharge conveyor: individually adjustable Only perfect blisters are accepted by the pickand-place vacuum function and transferred to the cartoner. The speed of the conveyor can be adjusted independent of the main drive of the blister machine. This allows the integration of a downstream machine tailored to requirements. Operation, format changeover and cleaning The central touchscreen control system with 3-D visualization simplifies operation. Tool-free format changeovers are carried out quickly as they involve few format parts. A special format parts trolley facilitates transportation and lifting for quicker and easier format changeovers. The GMP-compliant design of the UPS 5 eliminates inaccessible corners and edges. This alleviates cleaning to ensure maximum pharmaceutical safety. The innovative door sliding and closing mechanism offers optimum accessibility and reduces the sound level. Line integration and data acquisition Besides these technical features, the UPS 5 is compatible with state-of-the-art production data acquisition systems. A separate production data acquisition (PDA) system can be incorporated into the TouchControl operating system while the central line control system SCADA is optionally available for full integration with downstream machines. These solutions allow the evaluation of shift, batch or date related data. Furthermore, statistics as well as machine settings and control measurements are documented

12 The highlights of the Blister machine UPS 5 Technology Servo-regulated indexes and blister transfer Modular, enclosed stations Easy-to-exchange heating plates Universal forming station for all types of forming materials Large forming depth and suitable for large-sized blisters Innovative and intelligent technical solutions for sealing, embossing, perforating and punching Individually adjustable speed at discharge conveyor adaptable to the downstream machine Operation Self-explanatory operation via touchscreen with 3-D visualization Fast and easy, tool-free format changeover Easy servicing aided by pneumatic valve functions Plug-in tools minimize changeover times Design GMP-compliant machine design with innovative door sliding and closing mechanism for optimum accessibility and reduced sound level Scratch- and shatterproof safety glass doors ensure operator and product safety Modular, customized upgrades

13 Blister machine UPS 5 Technical data at a glance Output [1/min] max. 400 blisters Processable forming Al, PVC, PVC/PVDC, Sealing principle intermittent materials PVC/Aclar, PS, PET, PP for liquid dose products Format area Processable lid materials Al, paper/al, PET Index x width 272 mm x 284 mm Space required Forming depth max. 40 mm Machine width approx. 1,950 mm Reel diameter Machine height approx. 1,998 mm Lid material max. 460 mm Machine length approx. 4,000 mm Forming material max. 800 mm depending on modular length Net weight approx. 4,000 kg Forming material reel support Cutting and splicing table Forming material unwind Heating station Forming station Cooling station 1st index SyPro feeder Operating panel Lid material elongation Sealing station Cooling station Perforating station 2nd index Punching station Waste shredder Transfer 12 13

14 Guaranteed process quality from a single source. Customized solutions that meet every need from the concept to the fully integrated line. Example of a Customized Packaging System: a synchronized packaging line for the production of multiphase blisters with downstream secondary packaging. All process steps throughout the line are optimally coordinated and accurately monitored from the blister machine and cartoner to the packed cases on pallets. Uhlmann specialists develop and realize customized packaging solutions from the company s extensive range of blister machines, counting and filling machines for solid dose products in bottles, cartoners, stretchbanding machines, overwrapper, case packers and palletizer. Optimum combination of the line components ensures perfect integration into the respective production environment. The focus is not only on the systematic combination of machines but also on the production process as a whole. This includes design and feasibility studies, support in the development of packaging materials and blister configurations, the integration of additional components or software packages. Furthermore, as a general supplier, Uhlmann takes over responsibility for the project management and offers a one-stop turnkey service. Coordination and scheduling, logistical support, quality assurance, documentation, validation, communication, best possible workflows and on-site support are all part of the package.

15 Productive line combinations Requirement: packaging of solid dose products in blisters, cartons, cases and on pallets Blister machines B 1240 max. 250 blisters/min. B 1330 max. 300 blisters/min. UPS 5 max. 400 blisters/min. B 1550 max. 500 blisters/min. UPS 1030 ET max. 560 blisters/min. UPS 1030 max. 600 blisters/min. UPS 1040 max. 600 blisters/min. B 1660 max. 750 blisters/min. B 1880 max. 1,300 blisters/min. Cartoners C 130 max. 150 cartons/min. C 2155 max. 150 cartons/min. C 2156 max. 150 cartons/min. C 2206 max. 200 cartons/min. C 2205 max. 250 cartons/min. C 2305 max. 300 cartons/min. C 2504 max. 500 cartons/min. Packaging lines incorporating a blister and a cartoner module Blister Express Center 300 max. 300 blisters/min. and max. 150/300 cartons/min. Blister Express Center 500 max. 500 blisters/min. and max. 500 cartons/min. Stretch-banding machines, Overwrapper S 3015, S 3025, S 3040 max. 150/300/400 (500*) cartons/min. or 15/30/40 (50*) bundles/min. E 3025, E 3040 max. 300/400 (500*) cartons/min. or 30/40 (50*) bundles/min. E 3060 max. 500 cartons/min. or 60 bundles/min. Case packers E 4040, E 4046 max. 400 (500*) cartons/min. or 60 bundles in 10/6 cases Palletizer P 5020 max. 20 operating cycles/min. *optional output upgrade Requirement: packaging of liquid dose products in blisters, cartons, cases and on pallets Blister machines Cartoners Stretch-banding machines, Overwrapper Case packers Palletizer B 1240 max. 250 blisters/min. UPS 5 max. 400 blisters/min. UPS 1030 ET max. 560 blisters/min. C 130 max. 150 cartons/min. C 2155 max. 150 cartons/min. C 2156 max. 150 cartons/min. C 2206 max. 200 cartons/min. S 3015, S 3025, S 3040 max. 150/300/400 (500*) cartons/min. or 15/30/40 (50*) bundles/min. E 3025, E 3040 max. 300/400 (500*) cartons/min. or 30/40 (50*) bundles/min. E 3060 max. 500 cartons/min. or 60 bundles/min. E 4040, E 4046 max. 400 (500*) cartons/min. or 60 bundles in 10/6 cases P 5020 max. 20 operating cycles/min. Requirement: counting of solid dose products and packaging in bottles, cartons, cases and on pallets Counting and filling machines Cartoners Stretch-banding machines, Overwrapper Case packers Palletizer Integrated Bottle Center 120 max. 150 bottles/min. Integrated Bottle Center 240 max. 240 bottles/min. Labeler L 250 max. 250 bottles/min. C 2155 max. 120 cartons/min. C 2156 max. 150 cartons/min. C 2206 max. 200 cartons/min. C 2205 max. 250 cartons/min. S 3015, S 3025, S 3040 max. 150/300/400 (500*) cartons/min. or 15/30/40 (50*) bundles/min. E 3025, E 3040 max. 300/400 (500*) cartons/min. or 30/40 (50*) bundles/min. E 3060 max. 500 cartons/min. or 60 bundles/min. E 4040, E 4046 max. 400 (500*) cartons/min. or 60 bundles in 10/6 cases P 5020 max. 20 operating cycles/min

16 The complete range of support services A full range of top quality machines for diverse applications that is one aspect of Uhlmann s expertise. The other is the company s Customer Support & Services division. This center of excellence is based on four customer-focused modules: Format and Spare Parts, Professional Assistance, Machine Efficiency, and Process Reliability. These are subdivided into individual support services that serve the smooth Format and Spare Parts TopTools Spare Parts E-Shop PartsManager Top quality is a matter of course as far as new format parts, spare parts and tools are concerned. However, only a TopTool from Uhlmann guarantees maximum precision, plug-and-play reliability and top performance. Furthermore, original spare parts can be ordered quickly as required through the E-Shop in Internet or by using the electronic spare parts catalog on CD-ROM. Professional Assistance Maintenance 24h Service NetSupport Consistent machine availability is one of the prerequisites for efficient packaging. Preventive and proactive maintenance ensure production reliability. Online remote maintenance via NetSupport and the 24h telephone hotline provide prompt support in urgent cases.

17 operation of a machine or line after installation. They can be selected and combined as required on the basis of individual customer advice and support. Prompt, uncomplicated expertise offered by a well- coordinated, globally represented service team. For maximum flexibility, reliability and efficiency over the entire life cycle of a machine. In short: customer support services with added value. Customer Support & Services for maximum added value Machine Efficiency Upgrades Production Analysis and Output Optimization Production Support Efficiency has many facets. Effective workflows, state-of-the-art technology, optimum packaging materials, qualified personnel. To ensure full use of the potential of all different packaging processes, Uhlmann offers a whole range of solutions for greater efficiency. Process Reliability Personnel Training Validation and Calibration Film Competence Center Uhlmann meets all requirements in terms of process reliability. Support services cover TopmanTraining for well-trained staff, Validation and Calibration for tested and documented production, and the Film Competence Center for optimized packaging materials. You would like to learn more about the Uhlmann support services? Visit or request the brochure on the complete range of support services by sending an to info@uhlmann.de

18 The principle of success: thinking in pharmaceutical dimensions How can a medium-sized family company manage to not only retain but continuously improve its standing in today s world? How is it possible to use one s own strength to shape the pharmaceutical packaging market in such a sustained manner in competition with com petent machine construction companies? The answer is simple: Multum non multa. Quality not quantity. Concentration on one thing continues to be the company s motto to this day: the packaging of pharma ceutical products and nothing else. This is the strategic philosophy that defines Uhlmann s standards and governs their implementation as market-oriented concepts. This philosophy has given Uhlmann a leading edge: with more than 7,000 machines operating in 80 countries throughout the world. With a comprehensive product portfolio supplemented by the product ranges of Uhlmann VisioTec and KOCH Pac-Systeme. Proximity to the customer and proximity to the markets: alongside technological competence that is the second criterion for success. Uhlmann has over 40 representatives worldwide. Companies of the Uhlmann Group operate in the USA, Brazil, the UK, Sweden, Spain, Russia, Switzerland, Singapore and China. Altogether, some 1,300 people work in a corporate culture environment dedicated to total quality. Every day they readdress a single issue: optimization of the packaging process. You will find more technical information on Uhlmann machines at and in the detailed product brochures. Brochures are available through the website or can be requested by sending an to info@uhlmann.de.

19 The Uhlmann headquarters in Laupheim, Germany accommodate Development, Design Engineering and Production Multum non multa. Quality not quantity. Uhlmann Packaging Systems L.P. in Towaco, New Jersey, USA 18 19

20 Uhlmann Pac-Systeme GmbH & Co. KG Uhlmannstrasse Laupheim Germany Phone +49 (0) Fax +49 (0) Uhlmann VisioTec GmbH Uhlmannstrasse Laupheim Germany Phone +49 (0) Fax +49 (0) Uhlmann Höfliger Schweiz GmbH Talstrasse Arlesheim Switzerland Phone + 41 (0) Fax + 41 (0) Uhlmann UK Ltd. 6 Lakeside Business Park Swan Lane, Sandhurst, Berkshire GU47 9DN Great Britain Phone +44 (0) Fax +44 (0) Uhlmann Packaging Systems L.P. 44, Indian Lane East Towaco, N.J USA Phone Fax Uhlmann Pac-Systems Ibérica S. L. Sector Escultores Avenida de Colmenar Viejo, Tres Cantos, Madrid Spain Phone Fax Uhlmann Nordiska AB Gruvgatan Västra Frölunda Sweden Phone +46 (0) Fax +46 (0) Uhlmann Técnica Ltda. Rua José Bonifácio de Andrade e Silva, Bom Jesus dos Perdões (SP) Brazil Phone OOO Pharma Union Kutuzovsky Prospect 7/4 Building 6, Office , Moscow Russia Phone +7 (495) Fax +7 (495) Uhlmann Singapore LLP 1 Kim Seng Promenade # 14-03/04 Great World City East Tower Singapore Phone Fax Uhlmann Packaging Systems (Shanghai) Co. Ltd. Unit 1805, Silver Tower N. 218 South Xi Zang Road Shanghai People s Republic of China Phone Fax Concept and design: becker gmbh, Heidenheim 03/2011 e 2,000 We reserve the right to make alterations in line with technical development.