tablet line equipment

Transcription

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TABLET LINE EQUIPMENT
LEADING INNOVATION
World
World Wide
Wide Service
Services
Services
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Comprehensive Solutions for the Pharmaceutical
Phharmaceeuttical and Nutraceutical Industries
®
labelstar.com
capmatic.com
CREATING VALUES
Since 1964 ...
countlab.com
steelheart.ca
Since 1964 ...
Contents
Overview
3
Pharmaceutical Line - “From Concept... to Reality”
4-5
TM
SortStar | Bottle Unscrambler
TM
Street Fighter | Tablet Counters ( SF-100 & SF-200 )
TM
SynchroBlock
| Automatic Desiccant and Cotton Inserter
TM
BeltStar | Inline Capper
As part of the customer support service,
Capmatic ® established the validation department to assist customers with efficiency and
promptness; qualifying equipment with documentary evidence in a format that compliments
the existing qualified documentation.
6-7
The quality and reliability of our equipment,
along with our excellent service, engineering
departments and 75,000 square foot facility in
Montreal have made Countlab ® and Capmatic ® a
leader in the packaging industry.
8 - 11
12 - 13
14 - 15
TM
BeltStar | Torquer | Re-torquer
®
Road Runner | Rotary High-Speed Capper
TM
PG 27 - OTHER SERVICES
In any production line, Capmatic ® can also
integrate devices and software for Track &
Trace regulations which will soon become
mandatory in many states. Line monitoring
with data acquisition capabilities meeting the 21
CFR Part 11, IQ / OQ / DQ / FDS regulations are
also readily available.
16 - 17
18 - 19
LabelStar® & PharmaStar | Bottle Labelers
20 - 23
Line Integration Options
24 - 25
Line Management & Services
26
Other Services
27
VALIDATION PROTOCOL
DATA REPORTING
TRACK AND TRACE
LINE MANAGEMENT
and Services
DATA ACQUISITION & REMOTE MONITORING
Capmatic ® equipment is well-known for its performance and reliability. Capmatic ® designs and builds supporting
equipment delivering many benefits. Our products are installed globally and have proven to lower long-term
operational costs.
Capmatic ® combines innovative application engineering with a keen appreciation of packaging line productivity
and efficiency in each of its designs.
Capmatic ® has designed and delivered a variety of equipment for diverse liquid, tablet and powder packaging
applications. These systems are designed to improve the overall performance and efficiency of the packaging
line.
available to bring Line Monitoring to a world class standard. Monitoring is generally accomplished through the
use of terminals connected to each line component collecting selected data. This provides access for operators
to view the information collected and input details as required. In most cases these terminals can be linked via
Ethernet to a central PC.
UNSCRAMBLER
BOTTLE CLEANER
DESICCANT INSERTER
TABLET COUNTER
COTTON INSERTER
ROTARY CAPPER
SEALER
INDUCTION
The PC displays the status of all machines at a single glance. Access to individual operations of the linked
machines and OEE are also available for display and can be continually updated. These systems continuously
monitor all machines and accurately record downtime. They can also be used to generate reports that include
OEE (Overall Equipment Efficiency), total production and rejects. Data Analysis can be matched to any time
period, machine, operator and product depending on the information requested. This approach helps to free up
personnel from the task of data collection and processing and also eliminates the risk of inaccurate data entry.
BUNDLER
OUTSERTER
INLINE LABELER
ACCUMULATION
RE-TORQUER
CARTONER
CONVEYOR
PLC
Drives
HMI
DATA ACQUISITION
& REMOTE MONITORING
World-wide network of authorized partners contributing
to strength in consultancy, training, service and
maintenance.
PG. 03 - OVERVIEW
Line Monitoring Systems allow you to effectively follow and
record the efficiency of the operation for each piece of equipment
on the packaging line. Machine downtime can be identified
through the use of an integrated system that will report real time
OEE (Overall Equipment Efficiency) and downtime events for
review and further analysis in order to improve the line operation.
Manual collection of data and preparation of reports generally
does not provide the same degree of accuracy and is not as readily
World Class Design and Performance
FROM CONCEPT ...
21 CFR PART 11 COMPLIANCE
BUFFER TABLE
Bi-flow accumulation table
custom-built with a variety of options
SYNCHROBLOCK
REJECT FALLEN BOTTLE DIVERTER
TM
WIREWAY
SIDE TRANSFER
CONVEYOR
WIREWAY & SIDE TRANSFER
SWING OUT CONVEYOR
CAPMATIC® FEATURES AND BENEFITS:
Quality Equipment through Innovation
is our Primary Objective
for your Success!
t
t
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t
50 years of experience
Modular design
cGMP compliance
Slight or no dependency of external air source
Simple and repeatable change-overs without the use of any tools
Programmable recipes for different products and components
Low maintenance
Equipment fully enclosed with interlocked safety doors
Allen-Bradley P.L.C. with Ethernet connectivity and touchscreen control
21 CFR Part 11 Compliance
Batch process control reporting
Knowledgeable staff on hand
Long-time validation experience and support staff
Single point for FAT
Worldwide network
PG 25 - FEATURES & BENEFITS
BUFFER
TABLE
LINE INTEGRATION
... TO REALITY.
OPTIONS FOR TABLET LINE EQUIPMENT
Capmatic ® is a solution provider and a detailed analysis of the project is the key factor to ensure that the most
appropriate equipment is delivered.
Capmatic ® manufactures distinctive models of equipment that are essential to build a complete tablet packaging
solution. Capmatic ® can also integrate any piece of its equipment on any existing line. Using monoblock
technologies and integrating Capmatic ® standard equipment, these lines are designed to dramatically downsize
the overall required footprint.
Generally our solutions will decrease the change-over time, ease the cleaning process and increase the overall
efficiency, productivity and profitability. Ideal for the pharmaceutical, nutraceutical and healthcare industries, our
new compact tablet line of equipment will exceed your every expectation.
Line Integration Options:
t
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Metal Detector
Checkweigher
Desiccant and Cotton Inserter
Induction Sealer
Neck and Body Bander
Outsert Applicator
Coding Device
Cartoner
Bundler
Case Packer
On occasion, customer requirements demand a need
for peripheral equipment that may not always be part
of Capmatic ® manufacturing program or expertise. In
these cases, we are always open to recommend
specific options or third party machines, based on our
experience in the industry, or to incorporate
machines selected by our customers.
We will propose options that will enhance the production of the line and lead to higher performance
and reduced down time.
*S
Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute.
PG 05 - PHARMACEUTICAL LINE
Line equipment options and integration are important on any project. They ensure efficiency of the line and a
quicker return on investment.
TM
SORTSTAR
The Flexible Bottle Unscrambler without Change Parts
The PharmaStar TM comes with the most recently
developed labeling head from the Capmatic ®
engineering team, the HS 100 & HS 150. This head
utilizes a stepper motor capable of handling labels
up to 150 mm in height and can dispense labels at
speeds of up to 60 meters per minute (196 feet per
minute).
HIGH CAPACITY CHARGER
With splicing table
for longer autonomy
The PharmaStar™ automatically keeps track of
every faulty container throughout the system
ensuring that all flawed containers are discarded
onto a motorized accumulation conveyor .
PG 23 - ROTARY LABELER
FOR ROUND BOTTLES
The PharmaStar TM is a high speed pressure sensitive labeling machine for round bottles using a star wheel system
to properly present the bottles to the label applicator. Since the bottles are guided inside a star wheel pocket by
inline rollers, the system relies on the entire body of the bottle to properly present itself to the peal plate, ensuring
perfect placement of the label every time.
VISION INSPECTION SYSTEM
For Quality &
Integrity Control
TECHNICAL DATA
“Fast, Elegant
Elegannt andd Compact...”
Desi
ned
Designed
Designe
Des
gn
ed for Reliabilit
Reliability
Applications:
Round | Square | Rectangular Bottles
Speed:
Up to 300 BPM*
Air Consumption / Supply:
1 CFM (28 L/min) at 90 psi (6.9 Bar)
Power Supply:
220 VAC, 15 Amp, 3 Phases, 60 Hz.
Machine Dimensions:
W: 2350 mm x D: 2700 mm x H: 1905 mm
W: 92 in. x D: 106 in. x H: 75 in.
FLRS
Faulty Label
Reconciliation System
Besides the standard reject system, the PharmaStar TM can
be equipped with Capmatic ® unique Faulty Label
Reconciliation System “FLRS”. This system is designed to
reject any faulty label before it is applied onto the bottle.
The faulty label is applied onto an independent backing
paper to ensure easy reconciliation of the faulty labels
after a production run and to comply with the industry
standards of track-and-trace capabilities. This results in
minimal product waste as a bottle will no longer be
rejected due to a faulty label. For final reporting, a 21 CFR
Part 11 data report is also offered as an option.
*Speed and performance criteria are subject to testing with actual samples. BPM = Bottle(s) per Minute.
**Air supply and consumption depends on selection of optional equipment.
TM
PHARMASTAR
Rotary Labeler for Round Bottles
PG 07 - BOTTLE UNSCRAMBLER
The Capmatic ® SortStar TM bottle unscrambler is designed to handle a wide range of plastic bottles.
Using centrifugal disks and adjustable guides, most bottles can run on this machine without the use of
any change parts. All mechanical adjustments are equipped with numeric counters for easy and
repeatable change-overs. Optionally most adjustments may also be performed electronically through
a user interface allowing for a smoother operating experience.
INTEGRATED BOTTLE CLEANER
ASSISTED BY VACUUM SYSTEM
Ionized air system to eliminate
static from plastic bottles
TECHNICAL DATA
“Fast, Elegant
Designed
Dessigneed for Reliability
Applications:
Round Bottles
Speed:
Up to 300 BPM*
Bottle Diameter:
Min. 10 mm (0.3 in.) Max. 85 mm (3.35 in.)
Bottle Height:
Min. 15 mm (0.6 in.) Max. 250 mm (9.84 in.)
Air Supply / Consumption
0 CFM **
Power Supply:
Machine Dimensions:
W: 1950 mm x D: 1445 mm x H: 2200 mm
W: 77 in. x D: 57 in. x H: 84 in.
INTEGRATED PRE-FEEDER HOPPER
TM
TM
STREET FIGHTER SF-100
High-Tech
Electronic Tablet Counter
g
The LabelStar ® family of inline pressure sensitive labeling
machines is a flexible and reliable way to handle all types
of bottles at speeds of up to 300 BPM*.
LabelStar® was launched over 20 years ago offering
efficient, versatile and easy to handle pressure
sensitive labeling systems for the Pharmaceutical
Industry. Three platforms were introduced :
2. LabelStar® System 2 - For any bottle shape
(Front & Back, Wrap Around, etc.)
3. LabelStar® System 3 - For Top and/or Bottom Label
Capmatic ® developed the LabelStar® with the
Pharmaceutical Industry always in mind. With that
philosophy a stainless steel mono-frame base was
developed, in which we integrated all electronic and
mechanical components ensuring a smooth, easy to
clean finish.
LABELSTAR SYSTEM 1
For one-sided label or
wrap around application
PG 21 - INLINE LABELER
1. LabelStar® System 1 - For round bottles
(Wrap Around)
To ensure flexibility of the equipment it was designed with
a multitude of interchangeable modules that can be added
or removed without any major modifications to the
machine. This gives you advantages and flexibility,
covering almost any labeling application you may
encounter in the future.
All machines can be equipped with a wide variety of
options. Any type of coding device can be supplied with
the latest in quality verification systems, such as: bar code
scanners, vision inspection systems , OCV inspection of
the lot #/expiration date, label code verification and label
presence sensors. All inspections that fail will result in the
defective container being positively rejected.
GUARDING SYSTEM
Available for increased
safety standards
As shown: Model SF-100TM
The LabelStar® family of inline pressure sensitive labeling
machines is a flexible and reliable way to handle all types
of bottles at speeds of up to 300 BPM* depending on the
container and the size of the label.
LABELSTAR SYSTEM 2/1 T
5 Panel Label Wiping Station
TECHNICAL DATA
Applications:
Tablets | Caplets | Hard Caps | Softgels
Speed:
Up tp 150 BPM*
Estimated at 100 Tablets per Bottle
“Fast, Elegant
Elegaant and
and Compact...”
Designed
Desig
De
signned for Reliabilit
Reliability
Counts: Up to 1,000,000 tablets per hour
[from 10 to 1,000 tablets per bottle]
Tablets Diameter:
From 2 mm to 20 mm
Capsules Size:
From 5 to 000
Bottle Diameter:
Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.)
Bottle Height:
Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.)
Power Supply:
Air Supply / Consumption:
0 CFM**
SF-100 Dimensions:
W: 1852 mm x D: 1300 mm x H: 1800 mm
W: 73 in. x D: 51 in. x H: 71 in.
LABELSTAR SYSTEM 1 - HS
Inline labeler equipped with
redundant Heads for “non-stop”
operation.
*Speed and performance criteria are subject to testing with actual samples.
BPM = Bottle(s) per Minute.
TM
TM
STREET FIGHTER SF-200
High-Tech
Electronic Tablet Counter
The Road Runner® is a continuous motion rotary plugging
/ capping system designed for reliability and accurate high
speed capping operations.
The “Pick & Place” system will ensure perfect placement
of any cap at any speed. Depending on the selected
options, the Road Runner® can easily handle child proof,
R.O.P.P., aluminum press-on with or without an orientation
system (IntellichuckTM), press or screw pumps and over
caps.
PICK & PLACE SYSTEM
With calibrated clutches
for precise torque control
PG 19 - ROTARY CAPPER
Available in many configurations and options the Road
Runner® can process from 40 to 600 bottles per minute
depending on the number of capping heads selected.
The final torque is engaged by either magnetically
calibrated slip clutches or servo motors which are
programmable directly from the touch screen control.
Quality of the finished product can also be inspected with
special sensors or vision systems to ensure that every
bottle coming out of the system has a well-positioned cap
with the pre-set applied torque.
INTELLICHUCKTM
For cap orientation
& press-on placement
POSITIVE REJECT SYSTEM
With multiple pneumatic
pushers rejecting faulty
bottles directly from the
outfeed starwheel
QUALITY CONTROL VISION SYSTEM
To confirm that the pre-set torque has been achieved
As shown: Model SF-200TM
TECHNICAL DATA
Applications:
Tablets | Caplets | Hard Caps | Softgels
Speed:
Up tp 300 BPM*
Estimated at 100 Tablets per Bottle
“Fast, Elegant
Eleggant and
and Compact...”
Designed
Deesignned for Reliability
Counts: Up to 2,000,000 tablets per hour
[from 10 to 1,000 tablets per bottle]
Tablets Diameter:
From 2 mm to 20 mm
Capsules Size:
From 5 to 000
Bottle Diameter:
Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.)
Bottle Height:
Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.)
Air Supply:
0 CFM**
Power Supply:
SF-200 Dimensions:
W: 4575 mm x D: 1750 mm x H: 1900 mm
W: 180 in. x D: 69 in. x H: 75 in.
**Air supply and consumption depends on equipment selection.
®
LABELSTAR
Inline Labeler
The StreetFighter TM electronic tablet counter is designed to handle tablets, caplets, capsules and soft gels. It is
capable of handling a wide range of different container shapes and sizes, all while being able to minimize the
change-over time through machined parts and simple latching mechanisms.
From the vivid solid-state tablet channels and distribution manifold to the programmable bottle feeding system, the
StreetFighter TM is the new standard for electronic tablet counters. Visibly recognized for its improvements in Overall Equipment Efficiency (OEE), reduction in change over time, and simplification of daily operations, it is easy to
see why the StreetFighter TM is at the top of its category.
PG 09 - TABLET COUNTER
Countlab ® StreetFighter TM electronic tablet counter is a technological innovation which combines speed and accuracy in a compact design. The StreetFighter TM (SF series) exceeds cGMP specifications and is designed to meet
future regulatory requirements. Countlab ® visionary design is combined with the most current state-of-the-art
computer processing, allowing for an effortless tablet counting experience.
BOTTLE HANDLING SYSTEM
Programmable bottle positioning
minimal change parts
FAIL SAFE VACUUM REJECT
System with mechanical
tracking
The StreetFighter TM tablet counter also offers a complete
operational system that doesn’t need any compressed air
and has very low maintenance requirements.
PRECISION TRAY DESIGN
Quick release assembly
tablet flow control
TECHNICAL DATA
“Fast, Elegant
Designed
Designe
Des
gned for Reliability
Applications:
Vials | Round | Oval | Square | Rectangular Bottles
Speed:
Up to 300 BPM*
Bottle Sizes:
10 mm to 160 mm
Bottle Diameter:
Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.)
Bottle Height:
Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.)
Air Supply / Consumption:
0 CFM**
Power Supply:
HIGH EFFICENCY OPTICAL SENSORS
ORS
Capable of reading tablets
as small as 2 mm in diameter
TM
SYNCHROBLOCK
Desiccant and Cotton Inserter
This unique available option acts as an important source of information and offers the security of knowing the
true torque value of every container. Not only does this option display the applied torque but it also rejects any
container that is out of spec.
With its cGMP design and 21 CFR Part 11 compliance, the BeltStar TM has all you can expect from a torquer /
re-torquer. Offering exceptional quality, performance and an extensive variety of options, the BeltStar TM can be
considered a fully loaded high-end torquer / re-torquer.
PG 17 - TORQUER | RE-TORQUER
Enclosed with a high-quality stainless steel surface and a sturdy mechanical system, the servo-driven BeltStar TM
machine is our latest innovation. Its technologically advanced system allows for programmable recipe driven
change-overs, the capacity to display true torque and the capability of 100% torque verification through the HMI
(Human Machine Interface).
PRESETS ( ACTUAL: B2 C1 )
CAP Ø
SET
TORQUE
33 mm
20 (in-lbs)
TOLERANCE
MAX.
MIN.
15
ACTUAL
TORQUE
25
20
40
REJECT STATION
25
20
15
0
START
STOP
ALARMS
MAIN
MENU
LIVE GRAPHICAL APPLIED TORQUE
On all caps with the capacity of
recording the results.
TECHNICAL DATA
“Fast, Elegant
Eleggant and
and Compact...”
Designed
Desiggned for Reliability
RECIPES
Applications:
Sachet / Canister Desiccant & Cotton
Speed:
Up to 250 BPM*
Bottle Sizes:
30 cc to 1500 cc
Bottle Diameter:
Min. 35 mm (1.3 in.) Max. 160 mm (6.3 in.)
Bottle Height:
Min. 50 mm (1.9 in.) Max. 300 mm (11.8 in.)
Power Supply:
Machine Dimensions:
W: 3700 mm x D: 1230 mm x H: 2000 mm
W: 146 in. x D: 48 in. x H: 79 in.
®
ROAD RUNNER
Rotary Capper
PG 11 - TABLET COUNTER
A fully integrated high speed electronic tablet counter. The
Countlab ® Street Fighter TM SF-200 TM combines two (2)
proven SF-100 TM modules with a complete series of
motorized conveyor feeding systems connected to a single
reject station resulting in a single line component rather
than two separate and distinct units.
With a unique stainless steel frame and panel control, this
new integrated design will facilitate the maintenance and
operation of the line, all while ensuring the expected high
speed performance.
EXAMPLES OF TABLET
AND CAPSULE FORMATS.
Tablet
Round Mini
Caplet
TECHNICAL DATA
“Fast, Elegant
Elegaant and
and Compact...”
Designed
Desig
De
signned for Reliability
Applications:
Screw | R.O.P.P. | Press On Caps
Speed:
Up to 600 BPM*
Cap Diameter:
12 mm to 75 mm
Bottle Diameter:
From 20 mm to 100 mm
Bottle Height:
Air Consumption / Supply:
1 CFM (28 L/min) @ 90 psi (6.9 Bar)**
Power Supply:
Unique centralized panel control
for the dual counter with data
acquisition capabillities, meeting
acquis
21 CFR part 11 regulations.
The SF-200TM comes
standard with a remote
monitoring feature and
allows communication to
any mobile device or
centralized monitoring
system.
Capsule
Pellet
Odd Shape
Odd Shape
TM
BELTSTAR
Inline Capper
Capmatic ® has redefined the meaning of quality and control with its line of BeltStar TM inline cappers. As part
of the company’s rollout of tablet packaging equipment, the BeltStar TM staggers its adversaries by providing
extensive control and accuracy when handling the bottles and tightening the caps.
Conventional Spindle Capper
Lateral container
holding belts
BeltStarTM Solution
Cap tightening
spindle
CAP
188 mm
[7 1/2”]
PG 15 - INLINE CAPPER
Without the use of conventional spindles, the BeltStar TM puts itself ahead of the game when it comes to inline
capping. The BeltStar TM uses servo driven belt systems to tighten the cap, giving it a considerable contact
area ensuring perfect control during the tightening sequence to achieve perfect torque control on every cap.
This innovative and superior method of inline capping offers a reduced number of rejects, therefore
improving the overall efficiency of the line.
Cap tightening
belts
Lateral container
holding belts
Container
& cap
CAP
7 mm
[1/4”]
Container
& cap
CAP
CAP
TIGHTENING
SPINDLE
DEDICATED CAP PICK-UP HEAD
Ensures accurate positioning of the
bottle with a quick release assembly.
The distinct mechanical design provides accessibility to
all mechanical settings visible to the user. Effortless
numeric counters help to deliver precise and quick
change-overs for any bottle configuration.
TECHNICAL DATA
“Fast, Elegant
Eleggant and
and Compact...”
Designed
Desiggned for Reliability
Applications:
Screw Cap
Speed:
Up to 300 BPM*
Cap Diameter:
12 mm to 110 mm
Bottle Diameter:
Bottle Height:
From 30 to 350 mm
Air Supply:
0 CFM**
Power Supply:
220 VAC, 1 Phase, 60 Hz.
Machine Dimensions:
W: 1116 mm x D: 1153 mm x H: 1673 mm
W: 44 in. x D: 46 in. x H: 66 in.
Designed as a standard with the capacity to handle a
wide range of flat, continuous thread caps, the BeltStar TM
offers quality performance and maximum controllability
for impeccable proficiency with inline capping.
MECHANICAL ADJUSTMENTS
Executed from the control panel guide
with numerical counters for quick
change-overs.
TM
BELTSTAR
Torquer | Re-torquer
Re-
The SynchroBlockTM desiccant and cotton inserter is capable of handling a wide range of round, square and rectangular
bottles with a capacity of up to 1500cc. It can be easily integrated and synchronized with other tablet counting
equipment.
The SynchroBlockTM was engineered and designed with space in mind. This unique equipment solution combines
two systems on a platform allowing for the smallest footprint possible, without losing speed, accuracy or
efficiency.
Containers are driven by a servo motor feed screw ensuring perfect synchronicity and allowing for complete
traceability of any container. Faulty containers will be rejected via a vacuum star wheel directly onto a single reject
station.
PG 13 - DESICCANT &
COTTON INSERTER
The SynchroBlockTM is designed for Pharmaceutical and Nutraceutical applications, it can be engineered in
numerous configurations to handle sachet desiccant, canister desiccant or cotton and desiccant mixtures.
Conceived and built for a tool less change-over system, it also has the capacity of feeding multiple desiccants and
inverted U-Shaped insertions.
OBLOCKTM
SYNCHROBLOCK
Canister desiccant
& cottonn inserter
TECHNICAL DATA
“Fast, Elegant
Eleggant and
and Compact...”
Desi
Desiggned for Reliabilit
Designed
Reliability
Applications:
Screw Cap
Speed:
Up to 300 BPM*
Cap Diameter:
12 mm to 110 mm
Bottle Diameter:
Bottle Height:
From 30 to 350 mm
Air Supply:
0 CFM**
Power Supply:
220 VAC, 1 Phase, 60 Hz.
Machine Dimensions:
W: 1116 mm x D: 1153 mm x H: 1673 mm
W: 44 in. x D: 46 in. x H: 66 in.
CANISTER DESICCANT INSERTER
Quick release assembly
tablet flow control
SERVO DRIVEN BOTTLE
HANDLING SYSTEM
Programmable bottle positioning
minimal change parts
POSITIVE TRACKING
Fail safe system
positive reject confirmation

tablet line equipment

Transcription

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