complete filling and packaging solutions

C O M P L E T E F I L L I N G A N D PAC K AG I N G S O LU T I O N S
RESPONDING TO THE WORLD’S PLANT MANAGERS, OPERATION MANAGERS AND ENGINEERS
FOR NEARLY 100 YEARS
Cozzoli Machine Company is a global leader in the design, manufacture, distribution, and
service of precision cleaning, sterilizing, filling, and closing systems. Quality craftsmanship has always been the cornerstone of our foundation and we are dedicated to continuing that tradition of excellence. The products we engineer today are designed to take you
beyond tomorrow, because at Cozzoli research and development doesn’t end when a
system is successful. We continually update our methods and equipment, integrating fast
moving technologies that shape the products we provide worldwide.
I am committed to
insuring that our products
are designed and manufactured to the highest
quality standards in the
industry and dedicated to
providing exceptional and
dependable service.
Joan Cozzoli Rooney
President
Cozzoli Machine Company
MARKET SEGMENTS
Pharmaceutical aseptic
Pharmaceutical non-aseptic
Cosmetic, health, beauty aids,
personal care products
Food, beverage, dairy
Chemical, paint, industrial products
2
3
HOW WE GET YOU UP FASTER...
AND RUNNING LONGER
The most responsive team for
all your packaging needs…
Our expertise lies in the engineering and
manufacturing of exceptional equipment,
custom designed to your specifications for
a multi-faceted turnkey operation. As a
single source provider of individual components
through full lines, our projects are defined by
your individual requirements.
Progressive Engineering…
We utilize on-going technologies with design
features that save time in product changeover
and enhance productivity. Some examples are:
• The use of the latest PLC’s makes operation
easier than ever, allowing the operator to
With a combined sixty years of work experience, Mario Della
monitor and adjust volume, speed, and
Fortuna and Morris Bekerman are two of the most respected
technical experts in the industry. They represent the quality
container size.
and loyalty of employees at Cozzoli Machine Company.
• Equipment upstream and downstream can
be controlled from the same control panel, ensuring a smooth running, integrated line.
• No-tool changeovers save time when changing product or container size. This capability
reduces set-up time and increases throughput particularly when running a wide variety of
products and containers.
Value Added…
Cozzoli will meet the specifications and level of automation you require with machinery of the
highest integrity. We’ll test and fine-tune your equipment in our state of the art 100,000 sq. ft.
facility before shipment to ensure the highest level of performance. A smooth start up eliminates
costly delays.
Unparalleled Service…
We boast over three generations of experience in the design and manufacture of precision
equipment matched with peerless dedication to technical service. When your line is down you
need fast service. Cozzoli’s highly trained field service technicians travel the world, providing
factory-direct assistance to protect your investment.
Extensive Parts Inventory and
Customer Service…
Regularly scheduled preventative maintenance minimizes downtime and assures trouble-free
operation. We maintain an impressive inventory of spare parts and are ever ready to assist
you. You are just a phone call or fax away from receiving prompt, courteous
attention from a Cozzoli customer service representative who will immediately
process your request.
From designers and fabricators to engineers and expeditors, sales
agents and representatives, customer service representatives and
service technicians, our dedicated staff will ensure that you receive
the most productive solutions with unsurpassed support.
Dependability…
The quality machines we build today, just as those built and still operating since the
1900’s, demonstrate the value that Cozzoli Machine Company places on reliability.
Rugged construction and dedicated workmanship you can depend on contribute to an
efficient, smooth-running operation.
4
FILLING
METHODS
Fill-to-Level
Fill-to-level fillers are especially suited for thin and foamy
products (such as cleaning solutions). The fill-to-level
fillers compensate for variations in container volume while
retaining cosmetic fill accuracy. All fill-to-level fillers
operate in the same principles as illustrated: gravity,
pressure, and vacuum.
Peristaltic Pump
Nothing but the tube touches the fluid, eliminating the risk of the
pump contaminating the fluid or the fluid contaminating the pump.
The complete closure of the hose, which is squeezed between a
shoe and the track, gives the pump its positive displacement
action preventing backflow and eliminating the need for check
valves when the pump is not running.
Time Pressure
Time pressure filling is accomplished by controlling the flow of the
product through the tubing. The product stays in the manifold that
feeds the tubes. A computer calculates the product flow time
needed based upon manifold pressure, nozzle size, and target
fill volume.
Diaphragm Pump
Diaphragm pump fillers are suited for corrosive chemicals,
abrasive materials, and delicate liquids (blood, insulin, and
plasma). This completely enclosed system eliminates air bubbles
on small fills and features accurate repeat fills.
Piston (industrial and aseptic)
Piston fillers are ideally suited for filling a diverse range of
products. These fillers are ruggedly designed yet precision built
for long trouble free operation. Product viscosities may range from
1 to 100,000 centipoises and above.
Rotary Time Pressure
Time pressure fillers are well suited for filling heavy viscosity
products. The nozzle is open to the product for a specified amount
of time to achieve proper fill volume. Proper fill is dependent on
three critical areas —— time of fill, pressure of product flow, and
filling speed.
Vacuum Powder
This totally enclosed system removes the possibility of product
contamination. Fill volume of each piston can be independently
adjusted during operation. Two to sixteen fill stations are available.
Multiple dose fills are made possible by simply setting the microprocessor. Product loss due to dusting is virtually eliminated.
COZZOLI MACHINE COMPANY
TEL (732) 564-0400
FAX (732) 564-0444
WWW.COZZO LI.CO M
5
LAB, PILOT, AND SMALL
PRODUCTION
Outstanding Features of Cozzoli’s
Heavy Duty Lab Equipment
Compact size - Designed for clean rooms or industrial settings and is ideal for labs or small
production facilities.
Plug and play - Easy to set up and even easier to use; plug in and connect to a bulk
supply container.
Easy to clean and sterilize - All parts which come in contact with the product are fabricated of
316L stainless steel. Easy to disassemble for cleaning and sterilizing. Suitable and designed
for autoclaving, steam and/or gas sterilization. No “o” rings or gaskets.
Built to last - Our small production machines are made to last for decades and built to handle
any factory setting including those of food, cosmetic, chemical, and paint facilities.
Highest level of performance - Designed for rapid changeover of parts to handle different
products and containers on the same unit.
Equipment available: Ampule hand sealer, screw capper, powder filler, liquid filler, washer,
air cleaner (not shown), bench model single valve piston filling machine (BMSV), and mini
BMSV (not shown)
Bench model single valve (BMSV) piston
filling machine with pedestal option.
Washer
Liquid filler
Ampule hand sealer
Screw capper
Powder filler
6
PHARMACEUTICAL PRODUCTION
(SPEEDS OF 600+ PER MINUTE)
Washing
Stringent regulations require strict compliance. Cozzoli’s versatile air cleaning and washing systems
offer ease of operation and simple changeover, making compliance both direct and cost effective.
Sterilizing
Cozzoli depyrogenation tunnels feature unidirectional air flow, process temperature progression
curves, and significantly reduced sterilization times. They provide the repeatable accuracy
necessary for successful validation, qualification, and reliable production capacity. Controllable
and reproducible process parameters simplify validation.
Other features include safe zone pressure balance, automatic container density control for better
temperature stability, friction-free container transport, and easy access to the tunnel interior for
cleaning and maintenance.
Filling
Cozzoli provides continuous motion fillers with speeds up to 600+ containers a minute. Our fillers
perform with outstanding accuracies of +/- 0.5% of fill volume or better. Production and cost
saving features include compact size and quick and easy changeover. All liquid contact parts
are made of 316 stainless steel and medical grade silicone to accommodate sterile requirements.
Check Weighing
The Cozzoli check weigher is the pharmaceutical industries’ state of the art system and uses
magnetic force restoration type weighing technology. This technology provides high speed/high
precision performance.
The system consists of a tare weight unit, a gross weight unit, and controls that identify and store
in the memory the net weight of each bottle, simultaneously transmitting this information to the
printer. Additionally, the controller will send a signal either to the reject system and/or the filler
for fine fill adjustment. The alarm will send a signal either visually (light tower) or audibly (buzzer)
any time a gross weight is over or under pre-set limits.
Stoppering
This high-speed stopper placement machine is capable of full or partial insertion of a variety
of stoppers into round bottles and uses smooth, continuous motion to complete its function.
Elimination of intermittent mechanical motion makes high-speed placement and part handling
attainable. These systems have a no tool changeover, make up and back up detection, PLC
controls, jog mode, and sanitary “wipe-down” cGMP design.
By adding optional equipment, i.e., make up and back up controls, the machine becomes fully
automated, making it usable with filling and capping equipment by means of up and downstream
transfers.
Vision Inspecting
Vision inspection at speeds of more than 600 containers per minute brings production throughput
to a new level with our vision system. You can inspect 100% of your products and ensure that
your shipments are defect free. Eliminate inspection personnel, fatigue factor, data collecting,
and recording.
Crimping
The final component to the Cozzoli filling and stoppering systems is the continuous motion rotary
crimper. Uniquely designed, it is capable of speeds of 600 + per minute and has the ability to
test and record the seal pressure of every closure. Automatic vial height adjustment is provided for
easy operator changeover and also is a safeguard against adjustment errors.
Trayloading
Utilizing the latest technology in robotic automation, the Cozzoli tray loader is designed for placing
vials into either three or four-sided trays for lyophilization. Featuring a contemporary design with
a stainless steel exterior, it is low, compact, and built to maximize laminar airflow effectiveness
where class 100 conditions must be met. Vials can be loaded in straight, staggered, or “N minus
1” patterns easily selected from the electronic control and display panel.
Barrier Isolation Technology
Barrier isolation technology offers cost savings over traditional cleanroom technology, and provides
better sterility assurance, contamination control, and safety.
7
INDUSTRIAL
PRODUCTION
Versa capper
Rotary piston filler
Filling
Whether you need volumetric, fill-to-level, or time/pressure (versa fill) filling, Cozzoli has the right
machine to meet your requirements. Our rotary and in-line fillers handle an array of products of
diverse viscosities (1-100,000 centipoises) and different size containers measuring from fractional
ounce to five-gallon units. We incorporate the latest technologies into our designs on a constant
basis ensuring time savings in product changeover and enhanced productivity. Flush-in-place capability is available for our rotary piston and fill-to-level fillers. This allows liquid contact parts to remain intact on the machine during the flushing process.
Our rotary fill-to-level series accommodates a diverse range of low and high viscosity products using
vacuum, gravity, pressure, or a combination of these filling methods.
Rotary piston fillers are fully automatic machines that accommodate a wide range of containers and
products of most viscosities at high production speeds of 600+ per minute.
High-speed time/pressure fillers are especially well suited for filling heavy products such as peanut
butter, relish, lotion, shampoo, industrial grease, and glue.
All rotary fillers can be combined for filling and capping in a monoblock design providing you with a
compact, space-saving, and cost-efficient combination that is easy to operate, change over, and
maintain.
Fill to level filler
Rotary fill to level
Capping In-line
The Versa Cap is a straight through friction disc capper designed to handle a wide variety of cap
shapes and sizes with minimal changeover time required. The Versa Cap can be built in combination
with any hi-speed rotary fillers in a monoblock design providing compact, cost-efficient operation.
The Versa Cap accommodates threaded caps, snap-on caps and over-caps as well as plugs.
Rotary
Torque controlled for precision capping of a wide range of container shapes and sizes, the multi-cap
rotary capper can be built in combination with any hi-speed rotary fillers in a monoblock design,
providing a compact cost-efficient operation. Rotary fillers can accommodate threaded caps, snap-on
caps and over-caps as well as plugs. This extremely versatile and effective machine is designed to
handle caps up to 70mm in diameter at a speed of more than 600 containers per minute.
Time pressure filler
Monoblock
COZZOLI MACHINE COMPANY
TEL (732) 564-0400
FAX (732) 564-0444
WWW.COZZO LI.CO M
8
COZZOLI UNPARALLELED, INTEGRATED LINES:
ACCURATE. DURABLE. FAST. DEPENDABLE.
ASEPTIC FILLING LINE
• 600+ per minute
• Full check weighing
• Vision inspecting
• High accuracy
INDUSTRIAL FILLING LINE
• 900+ per minute
• Fill any viscosity
• Filling methods for any industry
• High accuracy
9
SAMPLE FLOOR PLANS
FOR INTEGRATED LINES
ASEPTIC FILLING LINE
• Washing/sterilizing
• Filling
• Sterilizing
• Capping
• Checking/coding
GLASSWARE
WASHING/STERILIZING
FILLING
UNSCRAMBLER
AC
CHECK WEIGHER
AND FILLER
STERILIZING
INACTIVATION
CHECKING CODING
STOPPERING
EMERGENCY
STOP
START
GUJ
TRATS
YCNEG REME
POTS
BOWL SPEED
MANUAL
JOG AUTO
STOP
MAIN SPEED
R
YNAPMOC ENIHCAM
R
MACHINE COMPANY
START
STOP
EMERGENCY
WASHER
STOP
SPEED
CONVEYOR
BOWL
VIBRATORY
SPEED
MAIN
STERILIZER
TRAY LOADER
UNSCRAMBLER
CRIMPER
ACCUMULATOR
CAPPING
EXTERNAL WASHING
DECARTON
DOSING
EMERGENCY
STOP
PANELVIEW 600
ALLEN BRADLEY
7
4
1
8
9
5
6
2
3
0
PURGING
START
STOP
F1
F2
F3
F6
F7
F8
F4
F5
F9
F10
INDEX
SPEED
40
VACUUM
60
80
20
R
MACHINE COMPANY
0
100
6.25
[158.75mm]
ASEPTIC FILLING LINE
• Washer
• Tunnel
• Unscrambling/accumulating
• Powder filler
• Stoppering
• Crimping
EMERGENCY
STOP
START
MAIN
SPEED
CONVEYOR
SPEED
STOP
VIBRATORY
BOWL
R
MACHINE COMPANY
HEATER BANK
WASHER
STERILIZER
UNSCRAMBLER
POWDER FILLER
STOPPERING
CRIMPER
ACCUMULATOR
10
ASEPTIC FILLING LINE
• Washer
• Sterilizer
• Unscrambler
• Filling and Stoppering
• Crimping
• Accumulator
• Tray loader
STOP
START
6
EMERGENCY
STOP
SPEED
5
4
3
7
2
8
1
9
10
WASHER
STERILIZER
UNSCRAMBLER
FILLER &
STOPPERING
CRIMPER
ACCUMULATOR
0
TRAY LOADER
INDUSTRIAL FILLING
LINE
FILLER
CAPPER
LABELER
UNSCRAMBLER
ACCUMULATOR
COZZOLI MACHINE COMPANY
TEL (732) 564-0400
FAX (732) 564-0444
WWW.COZZO LI.CO M
11
COZZOLI
CUSTOMER SERVICE
When Jack Schrum needed a
machine for high volume glass
ARTICLES AND
A redesigned sixth bottling line at spirits manufacturer and co-packer U.S. Distilled
Products provides a 60-percent increase in speed over existing lines.
TESTIMONIALS
SPIRITS SOAR WITH NEW LIQUOR
FILLING/LABELING LINE
ampule sealing, he didn’t consider
any other company. He knew that
By Anne Marie Mohan, Senior Editor
minimizes changeover on the filler by limiting to three the number of bottle
sizes run: .750 mL, 1 L and 1.75 L. "We could do all of the sizes if we
wanted to,” explains Rowland, “but w e feel that it’s not efficient to fill the
smaller bottles, because the volume is just not there.” Due to the clean-running
operation of the line’s new MRM/Elgin-supplied filler, products of all viscosities
are run, from water-thin spirits to thick and sugary cordials. But the largest
volumes, notes Rowland, are in the spirits.
Cozzoli had the capability to do
what he wanted. When asked about
his experience with Cozzoli’s
Customer Service, he answered,
“Service has been excellent – we
think the world of Sam Alexander,
(Technical Service manager at
Cozzoli.) Since we are located
nearby, Sam can stop in
anytime – one of those 30-year
employees that does whatever we
need. Service and products are
what keep us coming to Cozzoli.”
—from an interview with
Jack Schrum of Rutgers University
and member of ISBER
Just as wine depends upon the perfect proportion of acidity and sweetness,
fruit and oak, and alcohol and flavor to create a well-balanced taste, U.S. Distilled Products Co. (USDP) is placing more emphasis on a balance between
short and long product runs, and own-brand versus co-packed products to
sustain its thriving business. Establishing a bottling facility in 1981 for its
own alcohol product lines, the Princeton, MN-based company later uncorked
its capabilities for other brands. Today, with a recent brand acquisition, USDP
has come full circle. “We’re trying to focus on a balance between our own
brands and our relationships with other companies, so that we can keep our
plant’s capacity at a very high level,” says Todd Geisness, general manager
and executive VP of USDP. Traditionally USDP’s strongpoint had been in
producing small runs of 100 to 200 cases of bottled liquor. Thus, it equipped
its six filling lines with versatile machinery that allowed for quick changeovers.
But, as its brands grew in popularity, so did its run lengths. This evolution,
coupled with the competitive nature of the bottling market drove USDP to
install a completely new line, outfitted to accommodate larger-volume runs
quickly and efficiently.
Today, USDP typically runs three lines per 10-hr day, four days per week,
maximizing the efficiencies of both its low- and high-speed equipment to
meet various filling needs. To take advantage of the new line’s speed, USDP
12
The heart of the ne w line is 51-nozzle MRM/Elgin Husky 5 RFL rotary fillto-level liquid filler that allows for gravity, pressure, or combination gravity/
pressure filling. This versatility was vital to USDP’s equipment selection, given
the company’s large range of product viscosities, and container sizes and
materials. “To change over from one mode to another is fairly simple and can
be done in about ten minutes,” says on top of the machine. Notes MRM/Elgin,
“The inherent difficulty of filling liquids like cordials is the sugar content. When
drive parts are below the fill level, the sugar can get into the mechanism
where it’s hard on cams, bearings and other machine parts.”
Rowland adds that he was also impressed by the filler’s ease of maintenance,
made possible by a centralized lubrication system, and the quick changeover
enabled by tool-less changeparts. Changing over from one product to another,
while retaining the same bottle size, is a 20-minute process, he notes, while a
full changeover can be accomplished in an hour and fifteen minutes. “If you
look at the amount of nozzles we have, that’s pretty quick,” he says. On
average, the filler runs at a 230- to 250-bottle/min rate, for a total of 15,000
to 20,000 cases/day.
According to USDP’s Geisness, after just more than a year and a half in
operation, the new line is virtually bug-free and is delivering “greatly increased
productivity.” Installing the ne w line to increase our production capability
enhanced our flexibility, and this has allowed us to become more efficient.
And, obviously, the more efficient you are, the more competitive you can be
when bidding on a contract. There is no doubt that our ability to be competitive
has resulted in a lot more inquiries from potential customers.”
Reprinted and condensed from PACKAGING DIGEST® October 2002. Copyright © Reed Business Information, a division of Reed Elsevier, Inc.
By Jack Mans, Plant Operations Editor
Biomune Company is a leading U.S. manufacturer of vaccines for the animal
health industry. With headquarters in Lenexa, KS, the company produces
more than 50 US Dept. of Agriculture-licensed products and serves customers
in 37 countries. Its manufacturing sites utilize state-of-the-art equipment and
standard operating procedures in the production of live and killed vaccines.
In June 2005, Biomune installed an integrated packaging line consisting
of a Model UT 36 rotary unscrambler, a Model VR2S-10 in-line monobloc
filler/stopperer and a BT 15 dual automatic tray loader, all from Cozzoli
Machine Co. (www.cozzoli.com), to run small vials ranging in size from
5 to 20 cc. The line is installed in a Class 100 clean-room. "Cozzoli wasn't
highest or lowest on our list when we started thinking about this project,"
says director of manufacturing Bill Krehbiel. "We looked at several other
machines, but we have three other Cozzoli machines in our plant, and we
have had good experiences with them, so we decided to stick with Cozzoli."
Glass vials, which have been sterilized by hot air, are delivered to the line on
trays, from which a worker manually pushes them onto the rotary unscrambler
table. The unscrambler delivers the vials single-file to a conveyor that transports them to the monobloc filler/stopperer. A slight plastic protrusion on the
side of the conveyor near the monobloc unit causes any vials that have fallen
over to drop off the edge of the conveyor into a bin.
At the entrance to the intermittent-motion monobloc unit, the vials enter a
feedscrew mounted beside the conveyor. The screw extends through the filling
zone of the unit and spaces and controls the vials for filling. The filler runs 10
vials at a time, and the feedscrew stops during the filling operation, holding
the vials while the filling takes place. The nozzles descend, creating a bottomup fill. The nozzles rise in conjunction as the product is being dispensed, so
as not to create any splashing or foaming. The feedscrew starts up again to
discharge the filled vials and deliver the next group of vials beneath the
nozzles. Each nozzle is served by a dedicated positive-displacement piston
pump that includes a suck-back feature to eliminate dripping. Both fill volume
and the amount of suck back can be adjusted manually to optimize the fill
accuracy, which is typically in the 0.5-percent range.
SMALL-VIAL FILLING
FINESSE
In response to the question of
why they selected Cozzoli to
manufacture vial washers for them,
Steve Panneta of Alk Abello replied,
“We usually choose manufacturers
based on experience and reputation.
The feedscrew ends at the discharge of the filler, and the vials enter a
starwheel that conveys them beneath the stoppering wheel. Stoppers are
delivered from an overhead hopper down a track to the wheel. The rotating
stoppering wheel picks up the stoppers, rotates in synchronization with the
starwheel and pushes the stoppers into the vials. The unit can insert
lypholization stoppers, which have a slot in the center and are pushed only
part way into the vials and regular stoppers, which are pushed all the way
into the vials. The filler/stopperer incorporates an upstream sensor to ensure
there are enough vials on the conveyor entering the unit and a downstream
sensor to detect unstoppered vials. The unit is controlled by a programmablelogic controller that stores the recipes for all of the products run on the line.
Vials leaving the stopperer continue on the conveyor, which makes a rightangle turn and delivers them to the Model BT15 dual-tray loader. An infeed
system directs containers onto the tray loader, where rows of vials are
pushed onto three-sided trays. This unit also incorporates an A-B PLC,
which counts the number of vials pushed onto a tray and diverts the vials
to the adjacent tray when the first tray is filled. A worker then replaces
the filled tray with an empty tray, and the process is repeated.
"The Cozzoli equipment is of high quality and built to last, and it is
relatively simple to set up and operate, since most adjustments do not
require tools," says Krehbiel. "Cozzoli also has an excellent service
department, so if we do need service, they take care of us immediately."
Reprinted and condensed from PACKAGING DIGEST® March 2006. Copyright © Reed Business Information, a division of Reed Elsevier, Inc.
We’ve been doing business with
Cozzoli for 25 years, and have had
excellent success with them from the
beginning. Cozzoli advances their
styles and we’ve advanced along
with them. We buy a particular piece
of equipment; a vial washer made
to order. We haven’t had to research
competitors in a very long time;
we’ve stuck with Cozzoli because of
their exceptional products. We are
a repeat customer – third machine
over the years – and we are
extremely happy.”
—from an interview with
Steve Panneta of Alk Abello
and member of ISPE
13
A HISTORY OF INNOVATION
AND PERSONAL ATTENTION
1922
1930
1953
1983
2003
Cozzoli Machine Company
(CMC) is founded.
CMC develops first
aseptic filler
CMC designs
first monoblock
CMC develops first line
CMC purchases MRM/Elgin
Corp. expanding the company’s
business into the food, cosmetic,
and industrial markets
CMC opens new
100,000 sq. ft. facility
in Somerset, NJ
ST
C E R T I F I CA
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SY
1919
IS O
90
01
14
:2 0 0 0
1895
1926
1943
1974
1999
2008
Elgin Manufacturing
Company is started
and develops first
industrial filler
CMC receives first patent
and is awarded first
prize at the Belgium
International Exposition
CMC provides fillers to
vaccinate US troops
CMC is named Drug
Packager of the Year
CMC becomes first US
based packaging machinery
company in our market
segment to achieve ISO
9001 certification
President Frank J. Cozzoli poses
with the outstanding Cozzoli
staff outside of the Somerset,
New Jersey headquarters.
COZZOLI
AT A GLANCE
• Application Analysis
- Application Engineering
- Product Testing
• Product Design
- Line/machine design
• Manufacturing
• Line Integration
• Validation
- Qualification
- Verification
• Installation
• Parts & Service
Genuine Factory Replacement Parts
Maintenance
Field Service
Service Contacts
FOR MORE INFORMATION PLEASE CONTACT:
Cozzoli Machine Company
50 Schoolhouse Road
Somerset, NJ 08873-1289
Telephone: (732) 564-0400
Fax: (732) 564-0444
sales@cozzoli.com
www.cozzoli.com
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