What is packaging? Packaging is the science, art, and technology of enclosing or protecting products for distribution, storage, sale, and use. OR Packaging is the process of design, evaluation, and production of packages. OR Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. Each industry has its own packaging systems which required different types of needs & machines. On the packaging machinery side, while a wide range is manufactured in India, the industry also imports machinery, especially at the high end. Pharmaceutical packaging industry encompasses all activities including package testing and validation, package designing, development, package prototyping and marketing of pharmaceutical products. The pharmaceutical packaging industry primarily deals with packaging, handling, distributing and storing of pharmaceutical products. Some of the Pharmaceutical Packaging categories are: Category Proces Cream/ointment/gel in tube packaging Tube filling process Powder in small jars /boxes packaging Powder filling process Liquid in bottle packaging Liquid filling process Tablet/capsule in aluminum pack or Tablet packing process blister packaging PACKAGING INDUSTRY Pharmaceutical Packaging Industry
Transcript
What is packaging?Packaging is the science, art, and technology of enclosing or protectingproducts for distribution, storage, sale, and use.
OR Packaging is the process of design, evaluation, and production of packages.
OR Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use.
Packaging contains, protects, preserves, transports, informs, and sells.
Each industry has its own packaging systems which required different types of needs & machines.
On the packaging machinery side, while a wide range is manufactured in India, the industry also imports machinery, especially at the high end.
Pharmaceutical packaging industry encompasses all activities including package testing and validation, package designing, development, package prototyping and marketing of pharmaceutical products. The pharmaceutical packaging industry primarily deals with packaging, handling, distributing and storing of pharmaceutical products.
Some of the Pharmaceutical Packaging categories are:
Category Proces
Cream/ointment/gel in tube packaging Tube filling processPowder in small jars /boxes packaging Powder filling processLiquid in bottle packaging Liquid filling processTablet/capsule in aluminum pack or Tablet packing processblister packaging
PACKAGING INDUSTRY
Pharmaceutical Packaging Industry
Example of Tube packing line
Product Product tank
1) Tube filling Machine
2) Cartoning Machine
3) Bundling /Wrapping Machine4) Casepacker
Machine
Product Transfer Product comes from the tank to Hopper of the machine through pipes.
Tube loading unit
Packed boxes comes at the outlet
Corrosion Hygienic High Electrostatic StandardResistant Design Frequency Removal Component
Tube filling process is commonly used in the pharmaceutical & cosmetic industry. It is a process of filling the product like ointment, cream or gel in laminate /plastic tubes or in aluminum tubes. As in pharmaceutical field mostly the product should be packed in clean room & & minimum wastage of the product done while packing should be kept in the mind. This is not possible manually by any person so tube filling machines are used.
Features of Tube Filling Machine:
Long Life
Yes Yes _Cartoning _ _ _
Process Heat Resistant
Tube filing process
Yes
No tube - No fill device which makes sure that filling does not take place if tube is not present at the filling station.
At the orientation station, when the tube is lifted, its presence is checked by a sensor and this signal is relayed to the filling station. Hence if a tube is not there, the dosing action does not take place and hence there is no fill.
If the tube is not ejected out by the ejector, the machine stops in order to avoid damages.
In case of any jamming on the indexing system, to avoid breakages, the load is sensed by the variable drive through the PLC & the machine stops automatically.
Blow off device and tail cutting arrangements to avoid the paste /
Over load clutch to protect the indexer and all the related shafts rods etc.
Solid state no tubes no fill device mechanism.
Tube holders are of spring loaded type to take care of any tube diameter variation.
Over load clutch to protect the indexer and all the related shafts rods etc.
Audiovisual Alarm Annunciation System for any abnormal conditions of the machine.
Comprehensive control panel with all protection features.
Sections in Tube Filling Machines
1) Tube loading unit:The empty tubes are first loaded in the cassette, which then travels through the guides to be held in the feeder by vacuum. The tube is then fed into the tube holder by the feederThe tube holders are fitted on the circular turret which intermittently takes the tube to all the stations.
Pneumatic Application: In this unit vacuum is needed to transfer the empty tubes from cassette to tube holders mostly companies give separate small vacuum pump only for this purpose we can suggest them our vacuum equipmentsAlso cylinders are used in high speed machines for loading the tubes.
2) Centering & Orientation unit:The tube then passes through the centering station which presses the tube fromtop and lodges it into the tube holderIt then travels to the orientation station for positioning the ‘I’ mark. Here the tube is lifted and revolved. The moment the ‘I’ mark comes in front of the scanner, the tube stops revolving and comes down.
Pneumatic Application: These two units also consist of cylinders which are mostly used in high speed machines.
3) Filling unit:It is then carried to the filling station where the dosing action of the piston in the cylinder forces out the required volume of material through the hose pipe onto the suck back device and then from the nozzle into the tube.
Pneumatic Application : In filling units both cylinders & solenoid valves are used the nos. of these are depend on the filling nozzles, maximum six nozzles machines are present in the market right now. Also in many machines there is flushing or cleaning unit before filling the product in tube, it is used mostly to clean the tube.
4) Crimping & ejection unit (For aluminum tubes):
Actuator used for filling process
The tube then travels through the individual pressing, crimping and coding stations after which it is ejected out at the ejecting station.
Pneumatic Application:Each unit i.e.crimping, pressing & coding cylinders are used.
5) Hot Air blowing station (For lami/plastic tubes):In case of lami/plastic tubes, after the filling station, the tube travels to the hot air blowing station where hot air is blown onto the inside of the end of the tube by a nozzle having holes on its periphery. The tube then goes to the sealing station where the tube is pressed and sealed. It then travels to the dual coding & trimming station where the tube is first coded with metal stereos on the seal and the irregular shape at the tube end is trimmed by a set of blades. It is then ejected out at the next station.
Pneumatic Application:Same as above for coding and trimming cylinders are used.
Important note: The machine which is fully automatic servo motor based & high speed consist of minimum 8-10 cylinders also same no. of solenoid valves are used. The machines which is low speed or semi automatic or induction motors based consist of minimum 3-5 cylinders & solenoid valves. Also fully automatic machines are 30% pneumatic equipment based consist of tubing, fittings, pressure regulator, pressure gauges and pressure switch mostly.
Tube loading unit Hopper
Tube filling machine
Tubing & fitting are also used in every machine.
In small or semi -automatic machine also cylinders are used.
Tube loading unit
Filling NozzlesTube conveyor
HMI Touch screen
Cartoning process is very common in all industries, mostly companiespacked their product in cartons.
In the pharmaceutical sector there is a huge need for a cartoning machine that minimizes to the least human contact with the product and at the same
attain a maximum speed needed, in cartons per minute.
system for the cartons from the magazine.Also, its link up with the various blister packing machines completelyautomates the packaging process for the drug which was not possibleso far with high outputs.
An extra-long powered conveyor to stack cartons which brings it to the magazineEasily accessible drives that are isolated from the product pathPosition indicators that enable quick tool-less changeover and can be replicated by even semi-skilled personnelAutomatic Leaflet folding & feedingRotary pre-folded leaflet pick-upLeaflet pre-insertion (for delicate products)Printing device for flap embossing / debossingTuck-in / Hot-melt carton closuresInk jet / laser jet coding unitCentralized lubrication systemBar-code security system
There are many types of cartoning machine some packed big product in a carton& some packed very small product of minimum 3gms also.
Cartoning process
Features of cartoning machine
time gives high output for its large volume products. It is a continuous motion, fully automatic, horizontal cartoning machine which can
This high speed is achieved by a specially designed Rotary pick-up
HMI
Push Rod assembley
Product conveyor
Pneumatic Application
In tube transfer unit where tube automatically transfers from tube filling machine to cartoning machine there also a cylinder is used.In rotary unit solenoid valves are used to control the on/off application of vacuum.High Vacuum is needed to pick the carton & open the fold in high speed for which only small vacuum pump is used.In push rod assembly also small compact cylinder is used for the movements of the
Cartoning Machines
push rodsIn servo based machines carton guard can be up & down automatically by using cylinders on both sides.For carton magazine unit also cylinder is used.For empty carton rejection also at the outlet cylinder is used.Besides this every machine consist of tubing & fitting also.
Carton pick up/rotary unit
Tubing, fitting & pneumatic equipment
There are many types of wrapping machine like simple wrapping or bundling machine,shrink wrapping etc.This machine is for over wrapping and sealing of rectangular cartons with cellophane or BOPP film. The films kept in Rolls are cut to correct size, wrapped over cartons and heat sealed. This machine is suitable for overwrapping rectangular shapedcartons like tooth brush cartons, cassettes, blade dispensers and other rectangular cartons used in pharmaceutical, cosmetic, food and similar industries.
Features Of Bundling machine:Use of low-cost BOPP film or in some cases the cheaper HMHDPE 50% less power consumption than shrink-wrappers All around protection from dirt and humidity Product visibility lessens possibility of handling damage and petty pilfering. Quick changeover with help of mechanical memory and position indicatorsUse of Tear-tape and printed film.Automatic transfer from upstream machine.
Bundling/wrapping/shrink wrapping process
Bundling machine
Product inlet
Product
Bundling process
Cylinders are used in cutting section, side heating of the bunch & also in collation unit.
Tubing & fitting
Features Of shrink wrapping machine :
Automatic CollationLow film consumption - Cost saving in lower film consumptionCustomized in feed and collectionGives a transparent good looking packing.
Pneumatic Application
Cylinders are used in collation unit to make bunch & forwarding it to next unit.For cutting of film by blade also cylinder are used.For side heating & pressing the film cylinders are used behind heaters.Beside this solenoid valves, tubing & fitting are used.
Series AFF can be mounted on the main air - line piping to remove t oil, water & foreign particles coming in the compressed air - line from
It extends the life of the precision filters & enhances the life of other
Removes water from compressed air
Water droplet removal up to 99%.
No electricity required.
Space Saving
Should be installed at the peak pressure in the line & as f compressor as possible for maximum efficiency.
Air-Line EquipmentsFIlTeRS
Series AFF, Main Line Filter
Series AMG, Water Seperator
the impurities like m the compressor.
r pneumatic
far from the
AF10 AR10 AL10
AF20 AR20 AL20
AF30 AR25 AL30
AF30 AR30 AL30
AF40 AR40 AL40
AF40-06 AR40-06 AL40-06
AF50 AR50 AL50
AF60 AR50 AL60
AF18 AR60 AL60
Residual pressure Release residual pre relief 3 port valve
⅛,¼, ⅜ , ½, 3/ 4, 1
Cross Interface M5 x 0.8 Allows piping in all ⅛,¼, ⅜ , ½
Pressure sw itch ---- Compact Sw itch
Check Valve ⅛,¼, ⅜ Prevents back flow
Pressure Sw itch w ith ⅛,¼, ⅜ , ½, 3/ 4 Compact sw itch & p Piping Adapter integrated into one
T- Interface M5 x 0.8 Re - directs the air f⅛,¼, ⅜ , ½,
⅛,¼, ⅜ , ½, 3/ 4, 1 component w ithout re
ATTACHMENTSPhotograph Port Size Func
Piping adapter M5 x 0.8 Allows installation or
AC55 6000 1
AC60 7000 1
AC40-06 4500 3/4
AC50 5000 3/4 , 1
AC30 2000 ¼ , ⅜AC40 4000 ¼ , ⅜ , ½
AC20 500 ⅛ , ¼ AC25 1500 ¼ , ⅜
Model Applicable Series Flow Rate Port SizeAC10 90 M5 x 0.8
Bowl Material PolycarRecommended Lubricant Class 1 turbine Regulator construction Relievin
Filtration 5 μAmbient & Fluid Temperature "-5°C t Set Pressure Range (AC 10 to 20) 0.05 MPa (AC
FRLAC SeRIeS
SPECIFICATIONSProof Pressure 1.5 MMax. Operating Pressure 1.0 M
essure in lines.
four directions.
from lubricator
iping adapter piece.
low
emoving the piping
ction removal of the
¼ ¼
¼ ¼
⅛¼
⅛⅛
Pressure Gauge Port Size
1/16
rbonate Oil (ISO VG32)
ng Type
μm to 60°C
25 -60) 0.05 to 0.85 MPa
MPa MPa
Series MBStandard Air CylinderBore Sizes: Ø32, Ø40, Ø50, Ø63, Ø80, Ø100, Ø125Features:
a Low friction with a special "fig. 8" seal.b High Kinetic Energy absorptionc Compact & Light weightd Hexagonal wench for easy & fine adjustment of
cushion valves.
Series MBB
End Lock type/ Air Cylinder
Bore Sizes: Ø32, Ø40, Ø50, Ø63, Ø80, Ø100
Features:
a Locking Option on either sides / both side of the cylinder.
b Manual Release of the locks also possible
c All standard options for mountings are same as MB
Series MB1
Standard Air Cylinder with Square Tube
Bore Sizes: Ø32, Ø40, Ø50, Ø63, Ø80, Ø100
Features:
a Space saving auto switch mounting
b Better Asthetics, as tie rods are covered by square tube
c Easy Cushion Valve adjustment
d Special "Figure 8 Seal" for low friction.e High Kinetic energy absorption.
