C96-A96BLISTER PACKAGING MACHINE WITH INTEGRATED CARTONER

C96-A96

WHEN PHARMACEUTICAL PRODUCTION NEEDS ARE:• Lower production costs per blister by increasing

production batch sizes• Products with large sales volumes• Faster introduction of new products to the market • Limits in production space• Larger blisters• Alu-Alu blisters• Blister standardising

IMA SAFE’s C96-A96 IS THE ANSWERThe C96-A96 super high speed blister Line responds to these needs and represents the highest level of mechanical achievement in Blister Packaging.

Its conception comes from the hard work done by a dedicated team of IMA Safe Engineers as well as the experience gained from having delivered more than 2000 medium and high-speed machines worldwide.

The C96-A96 was designed with the most technologically advanced concepts while guaranteeing high reliability and efficiency within the entire packaging process.

C96-A96

The C96-A96 is a high speed blister machine designed specifically for those customers who need to run uninterrupted large batches with fast and frequent changeovers and from 2 to 3 lanes during production shifts.

C96-A96

The IMA Safe C96-A96 blister line has been designed for the highest outputs and efficiency that can be reached in the world: 1300 blisters/minute and 450 cartons/minute. The line concept is based on continuous motion. Continuous motion offers significant advantages with both material forming as well as the handling of products with different shapes and sizes by way of simple and efficient feeding systems.

The integrated high-speed A96 cartoner, designed specifically to be used with the C96, uses positive blister transport and is an evolution of the first system which was designed by IMA in 1976. Integrated monobloc machines with positive blister transport achieve the highest possible machine efficiencies and outputs. The A96 features fast and easy changeover and cleaning which helps reduce downtimes to a minimum.

The C96-A96 can also include optional features which further eliminates the need for operators so that non stop production can be obtained. The CF600 is a system to automatically load cartons to the A96 with a robotic arm; leaflets can be taken off a reel and do not need to be hand feed into a “GUK” by an operator; an automatic loading and splicing system can be also be installed so that the C96-A96 will be in constant production.

The C96-A96 monobloc machine continues the IMA blister philosophy that was first applied, in 1989, to the C90-A91.Designed with balcony construction and for easy changeover, the C96-A96 handles all materials, incorporates a PC as an operator interface and controller, and has an integrated connection between the blister machine and the cartoner.

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FORMINGPVC, PVC/PVDC, ALU, ACLAR®, COC, PP: all materials can be handled resulting in high quality blisters with excellent barrier properties and top performance rates.Material reel diameters can range from 400 to 1000 mm. which further reduces operator interventions.The PVC reel holder has been specifically designed to avoid stops in machine production.

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FEEDINGIMA Safe feeding systems are designed as the result of over 40 years of experience in the blister packaging industry and obtain a filling efficiency of 99.9%. These systems have been designed according to GMP principles which facilitate cleaning and reduce changeover times to a minimum. Fixed feeding positions assure the inter-changeability of parts and therefore help reduce overall expenditures. Extremely delicate and complex shaped products are handled with ease while assuring elevated production output.A specific department within IMA Safe is dedicated to product feeding solutions and includes several GMP Test Rooms for product feeding under controlled environmental conditions. Solutions are found which are based upon each unique product.

All IMA Safe feeding systems feature:• No operator assistance• Wide feeding bowls for maximum feeding performance• Continuous web motion• Higher camera efficiency due to continuous film motion granting greater

product stability in the pocket• Easy integration of multiple product feeding systems.

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C96-A96

SEALINGIMA Safe’s continuous roller sealing system evenly distributes heat and pressure without damaging the product or the forming material itself. A single contact or sealing line eliminates residual heat which allows blisters to remain flat. IMA’s specific pyramid grid creates a continuous seal around the entire pocket edge with uniformity in the laminating layers.

CARTON MAGAZINEThe elongated carton magazine on the A96 is fitted with a moving belt that facilitates carton transport towards its withdrawal. The system is also designed to avoid dust falling down on the mechanical parts of the machine.

CUTTING AND POSITIVE TRANSPORT

The cutting station uses quick change levers for fast and easy changeovers. The positive blister transport system also rejects faulty blisters or stacks proper blisters toward the integrated cartoner.

CODING AND PERFORATION

High precision coding and perforation systems are used in combination with an accurate web driving system to assure proper positioning and alignment. These systems also have individual disconnection levers for quick and easy changeovers.

LEAFLET TRANSPORTLeaflet transport from the folding unit up to the introduction is completely visible and accessible. The leaflet is pre-inserted into the carton through a double mobile blade for high efficiency. This system is exceptional effective when dealing with more difficult product presentations such as of alu blisters, PP monoblisters and very big leaflets

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SEPARATION BARRIERThis area has been specifically developed to create a simple barrier of separation between the blister and cartoning area while still allowing maximum accessibility for cleaning. The separation and the specific design of the system guarantees the minimum interaction between the two areas which helps to eliminate the possibilities of contamination.

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SPEED AND FLEXIBILITYThe C96-A96 can run to up to 1300 blisters/minute Blister cards, up to 98 mm long, can be produced on 3 lanes while blister cards with dimenions up to 145 mm long can be run on 2. Changing production from 2 to 3 lanes, or vice versa, can be quickly and easily performed. The integrated, balcony design, A96 cartoner can produce up to 450 cartons/minute and can handle the largest range of carton sizes that the market has to offer (carton sizes: width 35 mm up to 95 mm, length 70 mm up to 150 mm and height 12 mm up to 90 mm)

SPECIFIC FEATURES OF THE C96-A96 WHICH DISTINGUISH IT FROM COMPETITIVE SYSTEMS.

OVERALL EQUIPMENT EFFECTIVENESS (O.E.E.)The pharmaceutical industry is continuously striving to increase overall production efficiency levels in order to justify capital expenditure.The C96-A96 is the ideal solution to obtain this objective when high and medium level production speeds are needed. The monobloc, or integrated blister and cartoning machine, significantly reduces the number of productrejects, the consumption and cost of packaging materials and consequently the amount of time and energy which is need to produce a specific batch size. Complete format size changes can be completed within 90 minutes which dramatically reduces machine downtime.The entire machine has been designed to avoid any possible operator mistakes. Competitive machines with similar production capacities cannot obtain the high O.E.E. of the C96-A96.

SIZE CHANGEOVER AND CLEANINGComputer guided changeover with toolless quick pin release change parts can be performed in record time. A complete size changeover including blister size, product feeding system and new carton size, can be completed in less than 90 minutes.Cleaning, which can be a sensitive issue, is quickly and easily done due to the simple and ergonomic design of the forming, feeding, sealing, cutting, transfer, stacking and cartoning groups. The whole line has been built in compliance with GMP. Its balcony construction, smooth surfaces, oil-free belt drives and no hidden corners guarantee easy cleaning with no risk of cross-contamination. The critical units like feeding, cutting and carton magazine are designed in such a way to avoid any dust accumulation during the whole production process.

C96-A96

USER FRIENDLY DESIGNWith the ergonomic balcony design of the C96-A96 monobloc, all components are highly visible and easy to follow by the operator. From the forming station to the stacking station and through to the cartoner, the entire production process can be easily monitored throughout the machine. CAN-bus connections located in the rear of the machine drastically reduce cable space, thus granting easy access for maintenance operations. • All material handling can be carried out

from the front of the machine• Easy machine set-up• Interactive computer interface• Short cleaning time thanks to specific GMP

design.

OPERATOR INTERFACEA computer touch screen, with colour monitor and graphic representation, enables easy and intuitive management of the machines production and status. Production statistics, trouble shooting, including changeover instructions, maintenance and manuals can also be obtained through the HMI. Production data can also be seen in accordance to the Din 8743 specification. IMA Safe can also supply the high-resolution quality control Antares Vision system which is completely integrated into the single HMI computer interface. The Antares System uses high performance easy-to-learn, easy-to-use software and cameras which also allows for new products to be loaded in its system without the need for outside assistance.

HIGH-TECH SERVOMOTORSServomotors are used throughout the machine and grant intelligent operation and 100% precision. Servomotors are in the blister area, the connection and the cartoner.This technology has been applied especially to reduce changeover times and to increase flexibility in the use of very different packaging materials.

ERGONOMIC BALCONY DESIGN OF THE C96-A96 MONOBLOC

AN EXCELLENT INVESTMENTBecause of the high efficiency of the forming, driving and sealing systems, the C96 blister machine works with all materials pvc, pvc/pvdc, alu-alu, Aclar®, coc, polypropylene, reaching the highest standards in each case. The forming system of the C96 is based on functional small moulds working at very high speeds. This assures excellent temperature control, uniform and controlled distribution of the formed web on the pocket profile, and easy, very rapid size changeover.The cutting station with quick-change properties is positioned so that material fragments cannot get into the unit. The discharge system separates empty and part-filled blisters. Fail-safe: self-control logics are available for rejection implemented. The blister cutter works in such away as to simplify the transfer of the blister to the cartoner. The cartoner receives the blisters by means of an integrated blister stacker and positive blister transport system that guarantees maximum security coupled with a very high running efficiency.

C96-A96

INTEGRATED CARTONER

A96 continuous motion cartoner was exclusively designed to work in tandem with the C96 blister machine.The innovative features of the machine make it the ultimate solution in carton packaging:

◾ Complete balcony construction, meaning that jams can be easily removed

◾ Carton transport through tooth fitted belts keep the cartons in the correct position during the whole transport process

◾ Chain free to avoid cleaning issues

◾ The largest carton magazine in this range of machines (up to 2 metres long)

◾ Quick changeover in less than 15 minutes

The pushers operate from the rear. The machine is entirely accessible from the front.

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SPARE PARTSThe use of original spare parts is essential to guaranteeing perfect machine working order and providing full production efficiency.

Spare parts can be ordered from IMA directly or via the MyIMA e-commerce system and shipped to you within 24-36 hours.

IMA UNDERSTANDS THE NEED FOR EXCELLENT SERVICE AROUND THE WORLD

◾ Present in over 70 countries

◾ 10 branches providing sales and service

◾ More than 50 representing agencies

◾ 90 technicians from Italy supplying worldwide service

◾ 50 technicians from local subsidiaries and agencies

◾ 11 after sales supervisors

SALES AND SERVICES

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.

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TRAINING

IMA SAFE organizes specific staff training (certificate issued at the end of the course) in order to give the customer the possibility to achieve the maximum efficiency in the shortest time. The courses not only cover the functioning of the machine but also include practical aspects and daily operations such as size changeover, routine and special maintenance, troubleshooting, cleaning, quality control and other functions.

ADVANTAGES

◾ Efficiency increase

◾ Shorter change over time

◾ Faster error analysis

◾ Preventive maintenance

VALIDATIONIn the pharmaceutical industry, the validation of a production process implies the provision of documented evidence to demonstrate that the process is capable of producing a consistent product which conforms to predetermined specifications and quality criteria.

Upon request IMA will provide customers with a comprehensive package of documentation to support on-site validation procedures in the most simple and fast way. Different packages are available according to individual requirements.

C96-A96

SIZE PARTSIMA size parts are fully tested before being sent to the customer, which ensures that production can start immediately.

Originally manufactured size parts allow IMA machines to work at their highest production efficiency.Size parts are designed with a combination of detailed technical knowledge and practical know-how.

◾ Detailed experience with all types of packaging materials

◾ Detailed knowledge of the customer’s particular machine configuration

◾ Design and drawing systems based on the technical parameters of each machine model.

• Integrated Antares Vision System

• Different forming and lidding material reel-holding possibilities

• PVC hole perforating attachment for child-proof

• Pinhole detection on aluminium forming material

• Protection system for product/operator with laminar flow concept utilising over or under-pressure techniques

• Special air flow systems in contact with the product

• Automatic tablet loading unit from floor level

• System to feed multiple products simultaneously in the same blister

• Lidding material flexographic/laser printing

• Print registration on lidding and cold forming material

• Lidding material preheating

• Grid sealing on both blister sides (for cold-formed blisters only)

• Blister and carton coding (embossing, ink-jet, laser, etc.)

• Dust, forming and sealing fume extraction with centralized exhaust for operator’s safety

• Computerized spare parts management

• Computerized line machine statistical data collection

• Closed circuit cooling system

• Leaflet insertion (all commercial systems available)

• Booklet insertion

• Possibility of separation between blister machine and cartoner

• Hot melt glue system for various kinds of carton closures

• Trolley for easy disassembling/assembling of complete size parts

• Trolley for material transport

• 21 CFR Part 11 compliance

• Track & Trace solutions.

SIGNIFICANT OPTIONS OFFERED ON THE C96-A96:

C96-A96

C96-A96 TECHNICAL DATA

The dimensions are indicative and can vary depending on the optional groups chosen and machine lay out

PRODUCTION OUTPUT

3 rows Up to 1300 blisters/min

2 rows Up to 850 blisters/min

cartons Up to 500 cartons/min

BLISTER DIMENSIONS CARTON DIMENSIONS

Width 30-90 mm 35-95 mm

Length 65-145 mm 70-150 mm

Depth 3-12 mm 12-90 mm

MACHINE DIMENSIONS MACHINE WEIGHT

Length 13500 mm

18000 KgWidth 1500 mm

Height 2060 mm

Forming materialsAluminium laminate, PP, PVC, PVC/PVCD, PVC/ACLAR®, PET, COC and others

Lidding materialsAlu-Hard, Alu-Soft, Alu/Paper, Alu/Polyester, PP and others

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IMA S.p.A. IMA SAFE divisionVia I Maggio 14/16 - 40064 Ozzano dell’Emilia (Bologna) - Italy Tel. +39 051 6514111 - Fax +39 051 6514743 mktg.packaging@ima.it - www.ima.it

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