CARTONING SOLUTIONS FOR PHARMACEUTICAL, COSMETIC, FOOD AND OTHER PRODUCTS

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1 CARTONING SOLUTIONS FOR PHARMACEUTICAL, COSMETIC, FOOD AND OTHER PRODUCTS

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3 Table of contents A GREAT EXPERIENCE IN PACKAGING 2 THE FUTURE OF PACKAGING: RESPONSIBILITY AND SUSTAINABILITY 4 CARTONERS OVERVIEW 6 PHARMA 8 COSMETICS AND TOILETRY 10 FOOD, NUTRACEUTICAL AND OTHERS 12 HORIZONTAL CARTONERS 14 VERTICAL CARTONERS 17 FEEDING SYSTEMS 18 CLOSURES 20 ANCILLARY EQUIPMENT 21 TRACK & TRACE SERIALIZATION 22 SALES AND SERVICES 23 IMA SAFE IN THE WORLD 24

4 A GREAT EXPERIENCE IN PACKAGING SUPPLIED MORE THAN 4000 CARTONERS WORLDWIDE. Our cartoners are designed to run efficiently, reliably and with fast changeovers. They are easy to operate and at the same time ensure high operational standards. Maintenance needs are minimized. Each machine is designed to optimize valuable floor space with innovative solutions, such as carton transport by way of belts, tuckin closing solutions and balcony construction. The machines and feeder units are extremely flexible, enabling many types of products and pack to be processed. Our extensive knowledge and ability to provide customized solutions allow us to serve the pharmaceutical, cosmetics and non-pharma markets in the safest and most secure way. SINCE THE MID 1970s IMA SAFE HAS HAD THE REPUTATION OF INNOVATOR IN CARTONING TECHNOLOGY. 2

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6 THE FUTURE OF PACKAGING RESPONSIBILITY AND SUST Syringes placement into paper tray by robot GREEN PACKAGING IMA PRODUCES OPENING AND ERECTING SYSTEMS FOR CARTONS MADE ENTIRELY OF RECYCLED MATERIAL The Parenteral Paper Packs represent a new philosophy in packaging which uses completely recyclable materials for display boxes expressly designed for fragile products such as vials, bottles and syringes. Paper tray pick up Different configurations are available 4

7 AINABILITY WE HAVE ALWAYS BEEN ATTENTIVE TO WHAT HAPPENS AROUND US, READY TO GRASP ALL THE OPPORTUNITIES THAT TECHNOLOGY OFFERS TO ASSIST THE INDUSTRIES AS IT STRIVES TO PRODUCE RESPONSIBLY AND SUSTAINABLY. 5

8 IMA SAFE CARTONERS OVERVIEW Flexible and versatile, our cartoners assure an easy syncronization with both upstream and downstream machines and establish the link between the primary and the secondary packaging. By interlinking different machine types, entire packaging lines can be supplied. UPSTREAM MACHINES TYPE MODEL Aseptic liquid fillers Assembling machines X1/XL1 Blister machines Deep draw thermoformers FLEXA (AV, AS, AL, ASB, ALB) Flow-pack wrappers Jar fillers Labelers Rigid tube fillers Squeezable tube fillers HORIZONTAL A83E/EH FLEXA (CSD, CLD, CSDB, CLDB) Sachet and strips packers Stick packers Tea bag machinery DYNAMICA (S, L, V) Tablet counters Vial fillers and capping machines P.P.P Wallet machines Others VERTICAL VERTI CARE 6

9 SECONDARY PACKAGING IS A CHALLENGE FOR THE INFINITE VARIETY AND VARIABILITY OF PRODUCT COMBINATIONS MOTION SPEED UP TO (cartons/minute) DOWNSTREAM MACHINES Intermittent 140 Cartons labelers Intermittent 150 Case packing machines Check weighers Intermittent 160 Integrated case packing/ palletizers Continuous 180 Overwrapping machines Palletizers Continuous 400 Shrink wrapping machines Continuous 250 Stretch banding machines Tray packers Continuous and intermittent 120 Others 7

10 PHARMA The design and manufacturing standards to satisfy the pharmaceutical GMPs are applied not only on the primary packaging: IMA SAFE cartoners take into account specific control in terms of quality, cleaning and safety, necessary in the pharmaceutical industry. There is also a need to offer solutions capable of guaranteeing high levels of manufacturing efficiency in a sector in which there is a growing demand for small batches and/or different pack sizes for the same product. This is where the speed of size changeover and batch reconciliation play an important role. BLISTERS These products demand high production speeds as well as the possibility of producing packs with a huge variety of dimensions and configuration. TRAYS Often packed in trays, both thermoformed or paper, glass vials, ampoules, cartridges and syringes are very fragile products that demand a special care. VIALS, AMPOULES AND SYRINGES A wide range of very delicate products can be handled such as ampoules, vials, syringes and many others thanks to the use of robotic systems which have been applied to the most critical areas: product feeding and connection to the cartoner MEDICAL DEVICES In co-operation with GIMA Spa, specialist in assembly packaging solutions, we can supply lines for medical devices such as inhalers, spray, applicators etc 8

11 BOTTLES The flexibility of IMA SAFE enables the processing of this type of product, glass or plastic, whose shape can vary widely. Bottles are often accompanied by leaflet or booklets with irregular shape or which have to be positioned at a specific angle during the process packaging. TUBES Different types and shapes are available in the tubes field, whose application has been expanded to many other industries other than pharmaceutical. SACHETS AND STRIPS Innovative and user friendly, this kind of packaging is becoming more and more popular thanks to a considerable waste reduction of packaging material and consequently a smaller carton. FLOWPACKS Feeders are designed to be as flexible as possible in order to handle different sizes and shapes. Together with ILAPAK, manufacturer of flowpack machines, complete lines can be supplied. 9

12 COSMETICS AND TOILETRY Perhaps more than any other industry, cosmetics is a sector where creativity and new trends in design can be spotlighted with sophisticated packaging solutions. The use of high-tech coated or scratch-proof surfaces make the packs extremely delicate so special care is needed during the carton transfer to prevent any kind of imperfection. User-friendly and ergonomic, both horizontal and vertical cartoners are conceived to handle cosmetic products and accessories in diverse pack configuration. PERFUMES AND FRAGRANCES When it comes to perfume bottles the design must be unique and appealing. A special care with the feeding systems with or without the use of pucks is needed to handle these delicate products whose shape is most of the time unconventional. CREAMS AND MOISTURIZERS These packages require very often unusual liner shapes, different positioning of the leaflet or booklet, accessories such as sachet, spatulas and spiral tubes. Together with IMA SAFE COMADIS, manufacturer of tube and jar fillers, complete lines for cosmetics can be provided. 10

13 MAKE-UP Be it lipstick or lip-gloss, mascara or nail lacquer, compacts or palette, the aesthetic appeal is a common factor and these products must be captivating and creative. The same creativity, together with our knowledge, is used to create customized solutions in order to handle these products so different among them in terms of size and aspect, and whose shape is often unusual. TOILETRY SOAPS Either loose or overwrapped, the shape of soaps can vary considerably. Our cartoners have been designed to process these critical products without forgetting speed and easy cleaning factors. HAIR DYE Complete lines for hair dye can be provided. Besides the tube, any other elements such a bottle of developer of special finishing shampoo, instruction sheet, gloves and caps or any other tools are included in the package. 11

14 FOOD, NUTRACEUTICAL AND OTHERS IMA SAFE can provide rapid solutions that not only meet the needs of a highly dynamic market, but are also easy to be implemented in any packaging line. The need to cater for consumer demand has resulted a huge variety of product shape and sizes, for which the maximum flexibility of our equipment is needed. FOOD INDUSTRY CHOCOLATE, CHEWING GUM AND CANDIES All these products are processed at high speed, but their presentation tend to vary widely so that they require different treatment in each case. Chocolate, in particular, is a very delicate product and must be handled with care. Chewing gum can be processed either in bottles, blister, stick pack or sleeves and special solutions are needed. TEA, HERBS AND COFFEE Together with the Tea Division, the world leader in the primary packaging of tea, herbs and coffee, complete lines able to work non-stop at high speed can be supplied. Our cartoners can be easily dismantled too enable thorough cleaning in environments that are often saturated with dust. CONFECTIONARY BARS Robotic infeed systems provide the maximum efficiency and reliability for handling very fragile products whose shape and presentation can vary inevitably. 12

15 NUTRACEUTICAL Dietary supplements, natural or alternative medicine remedies are now part of our daily life with infinite forms of packaging such as blister, trays, sachet, strips or bottles. Cost-effective and versatile solutions are a must in this ever growing market where cost reduction and environment are a sensitive matter. Besides being flexible, IMA SAFE cartoners are easy to use, require very low maintenance and can also supply green solutions which reduce the ecological footprint, including the use of recycled materials. Moreover, thanks to the wide range of equipment of primary packaging within the IMA Group, IMA SAFE is able to supply competitive whole lines designed to give flexibility and lifetime productivity. TOOTHPASTE High speed lines are required for this product. Complete tube lines can be provided. OTHER MARKETS Whatever the product is, the carton is the most commonly used type of packaging. IMA SAFE can handle an infinite variety of products thanks to its feeding applications and robotic solutions. 13

16 HORIZONTAL CARTONERS DESIGNED WITH PRECISION, OUR RANGE OF HORIZONTAL CARTONERS - BOTH INTERMITTENT AND CONTINUOUS MOTION - ARE MANUFACTURED IN COMPLIANCE WITH INDUSTRY STANDARDS. Due to a wide range of in-feed systems, the machines can be flexibly used for many different products. Products can be loaded into the machine manually by the operator or automatically by means of mechanical or electronic synchronization units. 14

17 X1 SERIES Carton dimensions (MIN-MAX): A83 SERIES Carton dimensions (MIN-MAX): WIDTH A HEIGHT B DEPTH C A+B PRODUCTION OUTPUT WIDTH A HEIGHT B DEPTH C A+B PRODUCTION OUTPUT X cartons/min A83E cartons/min XL cartons/min Intermittent motion cartoner A83EH cartons/min Intermittent motion cartoner 15

18 HORIZONTAL CARTONERS FLEXA SERIES Carton dimensions (MIN-MAX): DYNAMICA SERIES Carton dimensions (MIN-MAX): FLEXA WIDTH A HEIGHT B DEPTH C PRODUCTION OUTPUT DYNAMICA WIDTH A HEIGHT B DEPTH C A+B PRODUCTION OUTPUT INTERMITTENT MOTION AV cartons/min AS cartons/min AL cartons/min ASB cartons/min ALB cartons/min L cartons/min S cartons/min V cartons/min for P.P.P Continuous motion cartoner Cartons dimensions according to the project 250 cartons/min CONTINUOUS MOTION CSD cartons/min CLD cartons/min CSDB cartons/min CLDB cartons/min Both Intermittent and continuous motion version 16

19 VERTICAL CARTONERS VERTI CARE is the ideal machine for top of the range cosmetic product, which require product extra careful handling and fast size-changeover. This high-tech cartoner is capable of packaging products such as perfumes, cream jars and lotion bottles having irregular shapes as well. VERTI CARE Carton dimensions (MIN-MAX): A B C A+B PRODUCTION OUTPUT Max cartons/min Continuous and intermittent motion cartoner 17

20 FEEDING APPLICATIONS AND ROBOTIC SOLUTIONS Cost effective and flexible feeding systems are available at IMA SAFE, which offer a wide range of solutions for both pharma and extra pharma fields. Both mechanical and robotized systems have been developed to facilitate modular feeding concepts which are necessary to meet the market s needs as well as product variants which are increasing over time. Many IMA feeding and robotic solutions are patented and provide feeding efficiency which cannot be reached by others in the market Application for flowpack Syringe feeding system and pick and place robot OUR INNOVATIVE PICK & PLACE IS NOT ONLY INTEGRATED IN THE MACHINE LOGIC CONTROL BUT ALSO AN ACTUAL EXTENSION OF THE MACHINE, ABLE TO ACHIEVE HIGH PERFORMANCES THOUGH KEEPING THE SAME SIMPLICITY AND RELIABILITY OF A ROBOTIZED LINE. 18

21 A WIDE RANGE OF PROVEN INFEED SYSTEMS ALLOW A HIGH LEVEL OF AUTOMATION IN THE HANDLING OF ACCESSORIES

22 CLOSURES AND TAMPER EVIDENCE SOLUTIONS MAIN CLOSURES GLUE CLOSURES SPECIAL CLOSURES Reverse tuck closure Glue closure Carton with inner partition Straight tuck closure Glue closure + tamper evident Carton with 5 th panel Carton with 4 th flap Carton with 5 th panel TUCK-IN, GLUE OR SPECIAL CLOSURES, LABELING OR PERFORATION: THANKS TO THE VERSATILITY OF OUR CARTONERS, ALL COMMON CLOSURE TYPES CAN BE IMPLEMENTED. CUSTOMIZED SOLUTIONS ARE AVAILABLE ON DEMAND. Carton with hinged lid TAMPER EVIDENCE SOLUTIONS EU Directive 2011/62/EU require the secondary packaging for prescription drugs to be equipped with a tamper verification feature. This means that non-conventional cartons are needed, as an alternative to glue or labels. IMA SAFE is constantly in touch with the producers of cartons in order to develop and test the solutions for tamper evident. Sleeve Glue 20

23 ANCILLARY EQUIPMENT The constant collaboration of IMA R&D with customers has made it possible to develop optional devices and other ancillary equipment applications aimed at maximizing the efficiency of the cartoners and increase quality standards, such as: MAXIMUM FLEXIBILITY FOR ALL TYPES OF LINE CONFIGURATIONS AND PRODUCT TYPOLOGY Specific equipment supplied by third parties Leaflet folding unit (prefolded, flat, from reel) Booklet insertion Huge selection of coding systems (embossing, inkjet, laser etc ) Bar code reader Camera Printing unit VIALS OR BOTTLE LOADER FEEDER FOR SYRINGES, DROPPERS, CANULAS AND OTHERS BOOKLET FEEDER SPOON FEEDER LEAFLET FOLDING UNIT PRODUCT AND LEAFLET FEEDING 21

24 TRACK & TRACE SERIALIZATION IMA GROUP SUPPLIES COMPLETE SERIALIZED TRACK & TRACE LINES STARTING FROM THE PRIMARY PACKAGING (BLISTER, BOTTLES, TUBES ETC.) TO THE SECONDARY PACKAGING (CARTONS, BUNDLES, CASES AND PALLETS). SHORTER LINE HIGHER EFFICIENCY The Integrated module to apply camera and ink-jet system is the ideal solution to have a shorter line and higher efficiency because of less units in the line and a constant control of the carton in the toothed belt transport. ONE LINE, ONE SOLUTION, ONE SUPPLIER FROM A TO Z 22

25 SALES AND SERVICES A GLOBAL APPROACH TO CUSTOMER REQUESTS. PROMPT AND EFFECTIVE TECHNICAL ASSISTANCE THROUGHOUT THE ENTIRE LIFE-CYCLE OF THE MACHINE. GLOBAL MANAGEMENT OF LINE MATTERS FOR COMPLETE LINES SUPPLIED BY IMA. DIRECT INVOLVEMENT OF ENGINEERING DEPARTMENTS AS REQUIRED. SERVICE IMA machines incorporate the latest developments in technology and are designed to ensure the highest production efficiency with low maintenance. To obtain top performance from ourmachines, IMA recommends technical training courses for personnel from Production (Operators, Technicians andsupervisors), R&D, Process Transfer Department and the Maintenance Department. Training courses can be organized at IMA s site or at the customer s plant and are taught by qualified IMA technicians. These Courses are tailor-made and modular and are designed to fulfil each individual customer s specific needs. Basic, Intermediate and Advanced training modules can be applied and special attention is given to the customized units which are fitted on the client s specific machine. These courses allow the customer s staff to operate the machine, maintain it in perfect working condition and explain how to carry out troubleshooting procedures in the easiest and fastest possible way. IMA can also provide course on improving O.E.E. and increasing production levels which are very important objectives in the pharmaceutical industry. To guarantee fast and efficient assistance and support, RSA Remote Service Assistance, enables IMA to provide support via modem and via tele-video conference. RSA enables an immediate analysis of the machine s status and working condition and can be of particular use in case if problems occur. SPARE PARTS The service of supplying original IMA spare parts fits completely with IMA s first-class maintenance service concept of taking care of the equipment as well as the customer s investment completely. The Spares Department has a very efficient delivery network, thanks to our Subsidiaries and Agencies, we are able to carry out deliveries of Spare Parts in the shortest time possible. Extended to most of the IMA machine models, My IMA Spare Parts is your virtual shop window available 7 days a week, 24 hours a day intended to provide immediate replies to enquiries, price, delivery time, quotations and order status. All that you need in just a few clicks! IMA SAFE provides prompt and effective technical assistance which covers the entire life cycle of its equipment. This assistance is provided by a dedicated team of experts able to meet our client s needs on a day to day basis. A customer oriented after sales service staff is what distinguishes IMA from the other manufacturers. 23

26 IMA SAFE IN THE WORLD IMA S.p.A. IMA Safe division PACKAGING SOLUTIONS Via I Maggio 14/ Ozzano dell Emilia (Bologna) - Italy Tel Fax mktg.packaging@ima.it INDIA IMA-PG INDIA PRIVATE LIMITED Plot No. R-677, TTC Indl. Area, MIDC, Rabale, Navi Mumbai INDIA Tel Fax: , sales@imapg.com CO.MA.DI.S. S.p.A. TUBE FILLING SOLUTIONS Via Piemonte, Senago (Milano) - Italy Tel Fax sales@comadis.ima.it IMA NORTH AMERICA INC. 7 New Lancaster Road, Leominster, MA USA Tel Toll-Free Fax sales@imausa.net IMA SWIFTPACK LTD. Swiftpack House, 3 Arden Road, Alcester, Warwickshire B49 6HN - United Kingdom Tel Fax sales@imaswiftpack.com For information on the IMA subsidiaries and sales offices, visit our website: (contacts section) 24

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28 May ZA IMA S.p.A. reserves the right to make any changes to the described machine characteristics. IMA S.p.A. IMA SAFE division Via I Maggio 14/ Ozzano dell Emilia (Bologna) - Italy Tel Fax mktg.packaging@ima.it -