Sturdy four-pack
The trend of using the ready-to-use disposable syringe as primary pharmaceutical packaging continues unabated. Entry-level versions which carry out compliance packaging all along the chain, from filling through to labelling, are particularly in demand. The modular machine combination presented by Bausch + Ströbel at Interpack 2008 is a fully automatic four-pack for production and labelling of disposable syringes in the medium capacity range.
The filling line presented at Interpack now offers the user a machine combination with a capacity of up to 5,100 disposable syringes per hour in the filling and closing area and 4,000 disposable syringes per hour in the labelling area. What's more, the modular structure of the machine design allows subsequent extension with the addition of further modules if required. The line starts with the SFM 5110 syringe filling and closing machine. The compact PLC-controlled monoblock machine is universally used to process disposable syringes according to the Hypac SCF method or similar systems. The design, structure and arrangement of all the units guarantee effective Laminar Flow for operation compliant to pharmaceutical standards in sterile environments. The steps of dosing and inserting the plunger stoppers are carried out entirely automatically. Depending on the nest size, the machine throughput is up to 5,100 syringes per hour. The dosing range per pump is between 0.15 and 50 ml. All the objects to be processed by the machine can thus be handled without any problems. All the operator has to do is to feed and remove the nests. The downstream transport operations take place automatically. The nested sterile syringe bodies are transferred to the transport system and moved precisely into position below the work stations. Filling and inserting the plunger stoppers take place via a two-position system. Centering of the objects and the freely programmable filling needle movement ensure optimum dosing results. Immediately there after, the plunger stoppers are positioned at the desired insertion height above the filling level, without exerting pressure.
After filling, the SET 8090, a syringe removal machine, first removes the nest from the tub. The filled and closed syringe bodies are then lifted from the nest in rows. This allows the subsequent steps in the operation to be carried out in individual transport mode, suspended by the finger rest. The empty tubs and nests are automatically ejected into bins.
Visual inspection
he third module, the TVK 7070 transporter, is a test unit for visual control of the filled, sealed syringe bodies. The objects rotate as they travel, in single file and continuously, past an illuminating device as the operator examines them visually with the aid of a magnifying glass. Any defective objects can be removed manually before they enter the area of the downstream labelling machine.
The final component of the line is the ESS 1001 labelling machine. This PLC-controlled, fully automatic machine works in cycles of up to 4,000 units/h and is a compact, complete solution for labelling and inserting plunger rods into the syringe bodies immediately following inspection. The plunger rods are screwed into the plunger stoppers. These plastic parts are fed in bulk by means of a transport combination consisting of a vibratory sorter in conjunction with a linear conveyor. The plunger rods are thus conveyed single file to the inserting tools. The pressure created inside the syringe when the rod is inserted is relieved by pulling back the plunger rod.
The next operation is labelling. The machine can work with all types of self-adhesive labels on rolls. The label dispenser is controlled by a stepping motor and automatically ensures gentle, secure belt transport according to the particular label length, thus guaranteeing that every single object is precision-labelled. All the machine functions are controlled and monitored by a series of electronic control devices. The finished syringes are then delivered for further processing.
