Originally Published PMPN April 2005
PRODUCT UPDATE
Flexible FillersA wide range of filling machines can help increase productivity by providing automatic features and creating flexibility.
Syringe Filling and Sealing
A fully automatic syringe-filling and -sealing machine can process nested disposable syringes from nearly all manufacturers. The H3-10 operates with 5 or 10 lanes and offers a maximum output of 10,500 or 22,500 syringes per hour. The machine's format spectrum ranges from 0.2 to 29 ml. In addition, the linear machine contains isolator capability and is characterized by its slim line. It is also compact in design. The company also offers the fully-automatic VVM crimping machine for vials and bottles. This machine can process containers up to a maximum diameter of 54 mm and is offered in 8- and 10-lane versions with outputs of 12,000 or 24,000 containers per hour. Inova, a subsidiary of Optima Packaging Group, Schwäbisch Hall, Germany; +49 7 91506; www.optima-ger.com.
Automated Filling
A machine is designed to automate the thermal-transfer printing, opening, filling, and sealing of pouches on rolls for medical devices. Since there are no bag perforations, the company reports that operators will not have any foreign material concern. A new, larger 5 x 4-in print area can be placed anywhere on the pouch. The machine's 2 x 3-ft footprint promotes easy installation, according to the company, and helps provide valuable cleanroom space. Printing options include one-color thermal transfer or a print-and-apply labeler that allows operators to add lot codes, bar codes, and symbols. In addition, validation ports for seal temperature, dwell, and pressure are included. PurePouch, Minneapolis; 763/444-4747; www.purepouch.com.
Filling System
A machine performs servomotor-powered filling and stopper/tip placement. It features cap-torque and index-ng systems for controlled delivery. Because it is compact in size, efficient in operation, and portable for relocating as needed, the Mini-Monobloc filling system is well suited to pharmaceutical, diagnostic, and biotech pilot plants. It can also be used for limited production requirements. With a footprint of 2 x 4 ft, the Filamatic Mini-Monobloc easily handles glass vials, plastic or glass tubes, microtubes, or precapped microtubes. Container feeding is offered as an automatic system with speeds up to 30 cpm, or as a manual system, with speeds up to 20 cpm. The machine fills from microdoses to 60 ml with accuracies of ±0.25%. Closure types include dropper tips, rubber stoppers, crimp seals, and screw caps. Product outfeed is performed by way of a removable collection bin or tray. A standard menu-driven, touch screen operator interface is included. National Instrument Company, Inc., Baltimore, MD; 410/764-0900; www.filamatic.com.
Aseptic Bag Filling
An aseptic filling machine is capable of filling bags sized from 100 ml to 20 L. Volume changeover occurs in less than 1 minute. The filling process can be validated to the highest aseptic sterility standards, with high production not seen in comparable machines. The filling machine can be configured to eliminate CIP and SIP processes by utilizing disposable bags and fluid-transfer sets, which can include an in-line final .22 filter. The integration of disposables into the production process makes it possible to manufacture with little fear of cross-contamination. The system is beneficial for many applications, including pharmaceuticals, biologicals, diagnostics, and others. The company can custom design the bags to be filled and offers choices of exit ports, tubing, fittings, and connections. The bags can be supplied sterile, with very short lead times. Advanced Scientifics Inc., Millersburg, PA; 800/724-4158; www.advancedscientifics.com.
Liquid Filler
An automatic in-line volumetric liquid filler is designed to meet the special packaging needs of the pharmaceutical industry. The FlowStar can be used for both short and long product runs and with both viscous and semiviscous products. It can reliably and accurately fill bottles in quantities from 5 ml to 20 L. The first module includes the fixed-base conveyor and servodrive nozzle bar unit. A lockable door permits maintenance access to mechanical drive components without compromising safety. The FlowStar can be equipped with 4 to 12 fill nozzles made of either 304 or 316L stainless steel. The nozzle bar unit supports an array of different nozzle configurations and is activated by a servodrive system that permits the programming of different filling profiles to handle many types of product and bottle shapes. Centering devices on each nozzle ensure that bottles are properly positioned before filling. Sensors verify the presence of bottles and automatically stop the machine if any are missing. The second module is a mobile filling unit that can be easily wheeled away for maintenance, cleaning, or exchange with another filling unit already set up. The FlowStar can accommodate electromagnetic flowmeter, mass flowmeter, or volumetric piston fills. Capmatic Ltd., Montreal, QC, Canada; 514/322-0062; www.capmatic.com.
Tablet/Capsule Filler
A tablet and capsule filler and capper features a twin-product hopper with pneumatic lift capabilities. The RTC 80 MB can count and fill tablets and capsules, insert cotton or desiccants, and seal off bottles with a flexible capper. The machine is controlled via a user-friendly touch screen panel. Its four-head counter and accurate matrix quad count enable stream filling through a sort wheel. A flexible dual capping station allows placing and tightening of caps. Other features include an optional reject-verification system, broken-tablet or -capsule detection, rotary intermittent motion with positive container alignment, and electric cap unscrambler and placing system. Romaco Inc., Pompton Plains, NJ; 973/616-0440; www.romaco.com.
Filling and Capping Machine
A company offers a vial-filling and -capping machine designed to help pharmaceutical companies achieve output increases. The FMB210 features an output of up to 85 units per minute, ideal for sterile filling of liquid volumes between 0.1 and 100 ml. The machine's peristaltic design provides easy product change and clean-up through the simple changing of the medical-grade silicone tubing. There is also 100% security against product cross-contamination, since the tubing is removed and changed following the production of each batch. All format parts are mounted by finger screws to allow fast, easy machine cleaning. For maximum performance, the machine also offers individual optimization of each function with automatic synchronization. A color touch screen on the control box can select the desired function from up to 30 stored recipes. The system also meets GMP standards for aseptic filling. Flexicon America Inc., Burlington, VT; 802/657-3232; www.flexiconamerica.com.
Syringe Filler
A manual syringe filler can fill up to 15 syringes per minute. The MTS series contains a single-head manual filler and closing system that can run most syringe types and closure configurations for single- and dual-barrel containers. The system also features a diving fill nozzle with tool-free removal capabilities, a metering valve for thin to thick products, and a plunger insert closure containing a feed track for plunger storage. ProSys Innovative Packaging Equipment, Webb City, MO; 417/673-5551; www.prosysfill.com.
Automatic Filling Machine
A company offers an automatic filler that can fill powders or liquids in both rigid and flexible containers. The Polyfill A-300 series of multiple-spindle filling machines can dispense products into from 2 to 12 containers per cycle, with each spindle driven independently for maximum flexibility. Highly adaptable to automatic packaging lines, the Polyfill can be custom designed for different filling needs and is available in servo-driven models. It is also adaptable to any style of machine, including horizontal thermoforms, cup or tray equipment, and vertical strip packagers. The product brings the capabilities of an auger filler to difficult, non-free-flowing pharmaceutical products on multiple-lane, high-speed, mechanized filling lines. AMS Filling Systems Inc., Honey Brook, PA; 800/647-5390; www.amsfillers.com.
Capsule-Filling Machine
A company offers a capsule filler that can fill up to 1400 capsules per minute. The GKF 1400, which combines the economical operation of the company's smaller machines with the operational sophistication of the larger GKF 2500, features an optional fixed- or adjustable-height dosing disk and a CGMP-compliant layout. It also contains optional 21 CFR Part 11–compliant software and enhanced segment cleaning. The machine operates at a speed of 140 cycles per minute, and can process a total of 84,000 capsules per hour. A capsule closing station with concave closing pins and a mechanical capsule-eject station are other features. Bosch Packaging Technology Div., Minneapolis, MN; 763/424-4700; www.boschpackaging.com.
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