The economic demands made on pharmaceutical packaging technology have increased considerably in recent years. Companies are explicitly opting for fast and reliable machinery that allows effective production. Above all, flexibility is becoming an increasingly important factor: the more types of solid dose products a machine is capable of packaging, the better. One packaging line that combines both advantages is the Blister Express Center 500.
Blister Express Center 500 is a single-lane packaging line that achieves batch changeovers within a matter of minutes, product changeovers in less than two hours and outputs of up to 500 packages/minute. A ramp-up phase is unnecessary. The integrated system is designed to handle solid dose product batches of between 30,000 and 150,000 blisters.
The consistent integration of the different components is responsible for the speed. All parts, from the heating station of the blister module to the closing station of the cartoner, are automatically positioned and self-adjust after a format changeover as well as during production itself. This results in a high standard of process reliability and continuous machine operation – start-stop phases are ruled out.
Efficient processes
Cost effectiveness is not just a case of high speed. The efficiency of a packaging line is another key factor. Amongst other things, this includes short changeover times. Uhlmann designed its Blister Express Center 500 so that a mechanical format changeover is possible within just 30 minutes using a minimum number of compact tools. The stations of both the blister and the cartoner module automatically adjust to the new package size at the touch of a button. Time-consuming subsequent adjustment is no longer required. Altogether, two members of staff need two hours at most to change over the line – from the last “good” pack of the previous product to the first “good” pack of the next, including cleaning and documentation. The process of material loading during production is organised in such a way that no interruptions are necessary. For instance, an automatic forming material splicer allows a new forming material reel to be joined without having to stop the machine.
A third aspect relevant to cost effectiveness is utmost flexibility. This is reflected, for example, in the large format area with a maximum blister size of 100 x 150 mm and a maximum carton format of 105 x 105 x 155 mm. The variety of configuration options provides another good illustration: as far as the cartoner is concerned, the customer can choose between different closing systems (tuck-in and hot-melt closure) and different marking systems (laser or inkjet printer, embossing). These are interchangeable without subsequent alterations to the basic machine. Additional components including cameras, code readers or leaflet folders as well as extra functions such as Track & Trace and the Scada line control system can be integrated. In other words, the packaging line is prepared for all future design alternatives and can be quickly adapted to production needs. The Blister Express Center 500’s flexibility is also apparent when it comes to the integration of downstream processes. The system can easily be combined with other components such as labelling or end-of-line packaging machines. Should production needs change, extensions can be carried out with minimum effort.
Reliability guaranteed
Although economic aspects play an increasingly significant role, every form of pharmaceutical packaging must nevertheless guarantee maximum reliability and safety standards. As with all Uhlmann machines, the 100 % good product philosophy also applies here. This means that only perfect products are forwarded to the next processing station. The good product philosophy even goes one step further. In the Blister Express Center 500, only good blisters are taken from the punching station of the blister module and transferred to the cartoner. Faulty blisters are cut with a different, recognisable contour that prevents any further processing. In turn, the cartoner only releases 100 % correctly filled cartons.
An ingenious safety concept additionally includes ease of operation and straightforward servicing. All stations and processes are within the operator’s range of vision, which makes them easy to monitor. The ergonomic design of the blister and cartoner modules as well as the sliding and closing mechanism of the protective doors allow easy access to all components. The Blister Express Center 500 is controlled by an intuitive touch-screen operating system that ensures reliable operation. All material is loaded from the operator side, so that distances are kept to a minimum.
Technology in detail
The cost-effective, productive efficiency of the Blister Express Center 500 derives from its features and configuration options. Pharmaceutical manufacturers can choose between four different feeding systems. The SimTap 3 k is particularly suitable for high web speeds. The basic module handles practically all solid dose products – whether of complex or standard shape or for aluminium or PVC blisters. Experts recommend the vibratory feeder for capsules and tablets of simple shape. Another alternative is the universal feeder, which is perfect for products that can be swept into the blister pockets easily. In the case of special shapes or products with a tendency to shingle, the MultiTab feeder can be integrated.
Prior to forming, the forming material is cleaned using ionised air and then heated by a format-free contact heating station. In the servo-driven forming station, direct cooling of the forming tool guarantees reliable processing of the forming material even at high speeds. The products are then filled into the blister pockets in accordance with the choice of feeding system. In addition to purely optical camera systems, an in-line active substance analysis using NIR technology from Uhlmann VisioTec can be integrated for subsequent product inspections. At the same time, the lid foil runs from the reel for customised marking. Track & Trace marks can be applied here, if required, in the form of codes. To allow the supply chains of prescription drugs to be tracked, unique marking from the smallest saleable unit is stipulated by law. By marking each individual blister, Uhlmann is already one step further. The sealing station of the Blister Express Center 500 is typical of the line’s flexibility. In the twelve o’clock position with a horizontal web, the sealing roller processes stiff blisters and large aluminium pockets. The two o’clock position is particularly suitable for thermoforming films, for which an effective cooling process has likewise been developed. Once embossed and perforated, the blisters reach the constant-motion punching station. Punch waste – partially filled or empty blisters as well as those for in-process controls – is automatically taken from the process and collected in different containers.
The perfect blisters are transferred directly to the product chain of the cartoner. No format parts are required for this process. A contact-free product inspection detects incorrect stacks with too many or too few blisters. The cartoner is fitted with a carton erecting device that can even handle carton blanks of critical quality. At the end of the cartoner, the finished products are released for downstream handling.
The Blister Express Center 500 combines the blister machine and cartoner as well as all inspection and code marking equipment in a compact, integrated system. In addition to the consistent monitoring of all relevant parameters, such as filling or temperature, the system also guarantees continuous production, fast format changeovers and – as a result – high capacity utilisation. The pharmaceutical packaging process consequently becomes faster, more efficient and more flexible, leading to greater cost effectiveness – with maximum reliability and safety assured at all times.
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