Symposium: Latest developments in packaging equipment and automation solutions
Target How some ongoing trends are having an impact on packaging equipment. Medical packaging possibilities. Update on different packaging technologies. Change from packaging equipment to packaging solutions, with giving update on automation possibilities. Some practical examples, recent realisations.
Agenda Some actual trends and influence on packaging equipment Update on medical packaging technology Packaging solutions / Automation Some realisations
Trends Flexibility / Sensibility (due to regular change regulations, smaller quantities and more complex new products) Influence on packaging Tool change Process accuracy Complex forming / packaging development Oxygen reduction Line Clearance / GMP
Trends Digitalisation Measuring / Analysing and documentation Influence on packaging More electronics, measuring instruments Communication with Scada.. Data exchange Generation of batch records Better process understanding
Trends
Trends More sensors will be brought in the machine for data collection
Trends OEE - TRS Tool manager Process data collection Spare parts Machine data Expert support Track and trace Predictive maintenance recipe communication
Trends Identification and inspection Influence on packaging Vision Digital printing UDI More solutions / less single standard equipment Increase in complexity
Trends Innovation Product and package related Influence on packaging More package developing / testing Use of different packaging materials New package concepts
Focus on packaging development (more importance on sampling)
Alternative packaging concepts (Skin for broad variation of products)
Agenda Some actual trends and influence on packaging equipment Update on medical packaging technology Packaging solutions / Automation Some realisations
Packaging possibilities for medical devices Thermoformed packs Pouch packaging Flow Wrap packs Tray packaging
Update Equipment Thermoforming
Thermoforming blister Advantages Big quantities, Multiple rows, lines in one cycle Complex form product protection Top and bottom film can be from different materials Integrity (high sealing pressure) High end vacuum and gas flushing possible Different opening systems Flexibility (different presentations, format change) Rigid and flex film applications Automation possibilities Integration possibilities: Inspection / printing / rejection systems Disadvantages Cost of investment Forming process with tools
Thermoforming versus Flow Wrap - pouch Advantages flow wrap Big quantities, single row Mono material No forming process, consistent film thickness Lower cost of investment Disadvantages flow wrap Less product protection Friction in material at the edges of product A lot of air is packed (thicker products) No rigid foil usable double sealing, risk for leakage at point of longitudinal seal. Only tear notch as opening feature possible
Small batches Flexible machines Compact Lower capacity Quick tool change
GMP Design Concept - doors - separation in technical and process area - minimal hidden spots in process area - minimal cable, hoses in process area - good visibility and illumination of the entire workspace - easy cleanable with minimal sharp edges or dead corners
Separation technical / process area
Tool Change KPS cutting Perforation Sealing die Forming die
Plug assist Servo controlled movement Forming tool
Options: Tool recognition The recipe control if the right tools are mounted in the machine (by means of magnetic switches) Some part are mechanically coded e.g. special radius at one side of the plug carrier Tool recognition
Update Equipment Tray Sealer
Tray Packaging Advantages Small / medium quantities Integrity product protection High End vacuum and gas flushing possible Material flexibility (lids, from reel) Disadvantages High material costs Storage of trays
Portfolio Traysealers Semi-automatic machines Automatic machines Traysealer Carrier lines T 100, T 200, T 250 T 700, T800 Semi-automatic machines for high end requirements T 260
Tray Carrier System Steps to automation T x with parallel belts T x with parallel and curved belt systems T x with parallel and curved belt systems as well as automized product loading
Update Equipment Pouch packaging
Pouch packaging Advantages Small quantities / batches Integrity High end vacuum and gas flushing possible Different materials Opening aid Disadvantages Difficult to automate No direct printer
Portfolio Chamber machines Tabletop chamber machines Chamber machines for the medical sector C 70, C 100, C 200, C 250, P 100, P 200, P 300 C 200 TC, C 300 TC, C 400 TC, C700 TC Free-standing chamber machines Vertical chamber machines C 300, C 350, C 370, P 400 AGV TC
Agenda Some actual trends and influence on packaging equipment Update on medical packaging technology Packaging solutions / Automation Some realisations
What can be automated in a packaging process? Unloading Down stream Up stream Process Loading
Product loading principles Preparation (orientation and separation) + handling unit From bulkware Conveyor Carrier Specific feeding Products are prepared in one or multiple rows for picking. Often vibratory bowls. Needles Plunger smaller components.. Products are ad random arriving on a conveyor. Orientation check with vision system. (Robovision) syringes pouches. Products are in carriers transported to the picking position Syringes devices inhalers Feeding system dedicated to product type Syringes ampoules vials
Product loading Needles / other components Products oriented and brought to pick and place position products flat and separated for picking
Syringe loading concept
Example for handling 600 plastic syringes / minute FBU = 380 UNTERFOLIE* FBO = 375 OBERFOLIE** Form R=6 540 7.5 135 112 9 5.5 34 45 10 360 10
Hopper + centrifuge system Conveyors Montageautomat 2 x Feeding System Syringes
Agenda Some actual trends and influence on packaging equipment Update on medical packaging technology Packaging solutions / Automation Some realisations
Automation Flexible packaging line
Example 1. Product: 4 x vial strip ca. 80 x 53 x 6mm 5 x vial strip 2. Carton size: approx. 102x63x67 mm 3. Shipping case : 4. Remarks: Important is flexibility in format change
Main advantages : Separation of technologies / not combined machines Simple technology Less influence of micro stops. Due to buffer creation. Flexible for future changes / new requirements.
Thank you!