At Emballage 2006 the IMA Group presented, in a space of more than 240 square metres, new machines and complete lines for the pharmaceutical and cosmetics industries.
SOLID DOSE PROCESSING
IMA offers the widest range of machines and technical solutions for solid dose processing requirements. Additionally, thanks to the acquisition of VIMA Impianti, a complete range for powder handling, washing systems and dedusting equipment can be supplied. On display, an innovative range of machines.
The KILIAN PRESSIMA rotary tablet press is for galenic and research applications. It is the only press of its type equipped with an interchangeable die table. This very flexible machine is designed for compressing small batch production and the instrumented version allows complete control of all production parameters. Good accessibility facilitates cleaning and maintenance. The machine can reach a speed up to 85,500 tablets/hour.
The KILIAN SYNTHESIS 500 is a mid-size tablet press machine designed for easy operation and cleaning. All components have been designed with smooth surfaces and can be easily cleaned. The die table can be taken out without removing the punches, while the force feeder and the tablet discharge are hinged and can swing out for easy access and cleaning. Since the mechanical and the compression areas are completely separated and sealed off, there is no risk of product penetration into the lower compartment of the machine: this means no risks of cross contamination, less maintenance operations, and 100% 'black spot' free tablets. The very well proven hydraulic overload system makes sure that punches don't break in the event of overload. With the state of the art quality control system 'ViCon' an automatic machine set up is possible. A touch screen comes standard with it. The SYNTHESIS 500 reaches a production speed of 360,000 tablets/hour.
The VIMA TWINVALVE is an innovative high containment valve system with simple design and maximum efficiency. This valve can be cleaned with dry compressed air, or with water/solvents and steam for actives/toxic products. It can be used as standard butterfly valve on Bins and retrofitted on existing installations.
Also on show, the VIMA HYDROBOX washing and drying cabin. The equipment can be fitted with two doors and a rotating platform for bins, tanks, drums, pallets and various accessories. The Air Jet Stream System and the Air Handling Unit on top of the box extremely reduce the drying times, avoiding energy losses and reducing installations costs. The machine can be equipped with a low, medium or high pressure pump allowing high flexibility.
IMA offers the widest range of blister machines on the world market (from 100 blister/minute to super high speed - up to 1,300 blisters/minute) with or without integrated cartoner.
The GIANT1, on show for the first time in France, is the new integrated blister line that fully responds to the most sophisticated production requirements worldwide.
Designed for both multinational pharmaceutical companies as well as contract packers, the GIANT1 can be considered a perfect alternative for just-in-time production of small and medium batches (up to 350 blisters/minute and 175 cartons/minute).
The machine concept has been based on the IMA philosophy of flexibility in operation and changeover combined with easy cleaning and less material/product waste. This has been achieved thanks to reliable feeding systems where IMA has had 30 years experience and a careful functional design in the main working groups that are completely servomotor assisted. High efficiency in production is assured as the blister machine and the cartoner are completely integrated.
Changeover times on the Giant1 have been reduced to unprecedented levels thanks to a limited number of size parts, which have been specifically designed to decrease their size and weight. Innovative solutions have been applied to the coding & perforation areas and the cutting station as been designed to weigh less than 20 lbs (9 Kg). GIANT1 in name and capability, but only 6 metres long.
IMA stood also in the forefront to solve the problem of the “product recall” faced by the drug manufacturers by applying a patented cutting system. This innovative solution guarantees that rejected faulty blisters cannot be matched in further packaging process due to their different shape. With the GIANT1, IMA confirms once again to be the global supplier in blister packaging.
IMA SWIFTPACK exhibits the SWIFTPACK SV2, a unique tablet counter that combines output and product quality. Leading edge technology in the SV2 Intellisense range features an advanced Electrostatic Sensing System, which not only counts tablets more accurately, it also ensures that the tablets meet key quality standards.
The SV2 counter achieves this leap in levels of quality control by virtue of an electrostatic field, which enables an extremely accurate assessment of tablet parameters, such as size, shape and mass. The tablet parameters are pre-set, and tablets are measured against these as they fall through and disturb the field, tablets that do not conform exactly to the pre-set parameters will be rejected automatically.
Swiftpack SV2 series offer manufacturers an accurate measure of product quality in terms of physical variance, a vital issue where dosage is concerned.
In addition, downtime owing to changeovers is reduced, as the SV2 counter will accept products of various sizes. The filling funnel has also been carefully positioned at the very front of the machine, to allow clear supervision of the filling process.
The SV2 counter is solid, robust and quiet in operation. Enclosed pipework adds to the aesthetic design of the machine, and ensures that it operates cleanly in hygiene-sensitive pharmaceutical environments. The SV2 is designed to surpass GMP specifications, with improved dust control, as well as quick-release fasteners for easy cleaning and maintenance.
The SV2 is available in either a single or twin configuration or in multiples of both, to give speed capabilities from 50 to 200 bottles per minute, dependant on count per bottle.
On show, a laboratory freeze-dryer by IMA-TELSTAR, the joint-venture established in August 2005 in the field of freeze-drying machinery for the pharmaceutical industry.
IMA-TELSTAR has completed its range of pilot laboratory freeze-dryers LYOBETA with the launching of the new model LYOBETA 15. This new freeze-dryer aims at covering the range which had been little considered up until now: that is to research and develop according to cGLP. FDA investigators consider that transfer of technology from R+D departments to the following phases: clinical trials and later commercial production, is carried out with lack of strictness and poor documentation practices. Therefore, they are emphasising on the concept of GxP as a quality oversight, comprising all practices in R+D and production processes.
The LYOBETA range of units is the answer to this need:
LYOBETA 35: 1.03 m2 of shelf surface; condenser capacity of 40 l.
LYOBETA 25: 0.68 m2 of shelf surface; condenser capacity of 40 l.
LYOBETA 20: 0.61 m2 of shelf surface; condenser capacity of 30 l.
LYOBETA 15: with 0.46 m2 of shelf surface completes the range; condenser capacity of 30 l.
Over dimensioned condenser of 40 and 30 l respectively offers the maximum capacity features in the market.
The main new feature of the LYOBETA units is the incorporation of a control system via PLC instead of the classic microprocessor commonly used in this type of equipment. This system, fully proven in the industrial models of the Series LYOGAMMA and LYOMEGA, guarantees maximum reliability and reproducibility in the process, totally adapting the equipment to cGLP. The system allows control of the freeze-dryer functions via a graphic HMI (Human Machine Interface) user interface. The user interface presents information in an attractive and intelligible manner on a graphic 6” touch screen, through which different data screens can be accessed by means of touch zones. Optionally, the equipment can be connected to different peripherals, such as a graphic recorder, printer or PC SCADA.
The main features of the new LYOBETA 15 are the following:
- The chamber, cubic in shape, is made entirely from AISI 316 L stainless steel and its interior is fully accessible for cleaning purposes.
- The chamber incorporates an automatic stoppering device for vials and a side flange that allows the connection of a three way valve manifold for the freeze-drying of CN 29/32 open flasks.
- It is equipped with up to 4 loading shelves, also made of “sandwich” type AISI 316 L for thermal fluid circulation, which allows prior product freezing and heating during freeze-drying.
- An additional shelf thermally balances the equipment.
- The clearance between the shelves can easily be modified, and is therefore adaptable for different types of products and containers.
- The condenser, which is also made of AISI 316 L, has a rapid defrosting device by means of electrical resistors
- The equipment’s refrigeration system, which works with air, is capable of to provide –80ºC in the condenser and -65ºC on the shelves. It only uses HFC gases, which are authorised for use both at the moment and in the long term
IMA LIBRA exhibits the SENSITIVE ECO New. The new version of the SENSITIVE ECO is a completely automatic labelling machine suitable for applying self-adhesive labels on vials or bottles (up to 150 vials/minute). It’s characterized by a very compact design, realized for easy application in line with packaging machines and up and/or downstream rotating accumulating tables. Its functioning is simple and effective. Label distribution and application are driven by automatic stepping motors and automatic synchronization system to the machine speed, whilst label spacing is kept by means of speed stopping with a photocell. The distribution unit enables the installation of the widest range of hot foil or thermal transfer printing units and bar code readers. This new version of the machine has been supplied with a user-friendly operator panel with START/STOP buttons and E-Stop situated at the machine front; installed inside the machine frame, there are electro-mechanical instrumentation and various power interlocks.
Another machine on show, that has been recently developed, is the SENSITIVE SVL labeler. It’s a new completely automatic labeling machine suitable to apply pharmaceutical optical stamps and “Italian bollino” on top of formed cartons. The machine has a compact foot-print (machine frame of 500 mm) and has been specifically designed for easy application in line with packaging machines. It has been realized, above all, keeping in mind a need for flexibility, an important feature that makes it possible to install the machine in limited spaces and to avoid expensive line changes, caused by new requirements for the application of “Italian bollino” and “Belgian vignette”. It could be also equipped with a Camera and its Vision System in order to show the initial part of the tracing system of the “Italian bollino”. Its compact design doesn’t limit the production speed that could reach, for cartons and blister, an output of 2,400 cartons/hour.
CO.MA.DI.S. exhibits the tube filler C960 which is suitable to handle plastic tubes with hot air sealing unit. The machine having a stainless steel structure and a new type of automatic empty tubes feeling magazine, has been completely redesigned complying with the highest manufacturing process standards. Innovative features of the C960 include a dosing pump that can be dismounted without using any tools and the control panel with a programmable display is easily accessible to the operator. The aluminium tube closing unit is available in standard with normal, double or saddle fold, while for the polythene, laminate and polyfoil tube is available hot air or hot jaws sealing technology. For plastic tubes it is possible to have different seal shapes on request. Thanks to the design criteria the machine allows an easy access to the four sides of the basement for maintenance operations. The C960 reaches a mechanical speed of 60 tubes/minute.
IMA, which offers a wide range of horizontal and vertical cartoners for the pharmaceutical industries, exhibits the new fast continuous motion horizontal cartoner: DYNAMICA. This new model completes our range of continuous motion horizontal cartoners at high speed with a production output of 400 cartons per minute. DYNAMICA has been designed combining several proven solutions including our innovative carton transport system. The machine design makes it simple to operate and its ergonomic design improves accessibility, cleanliness and simplified components loading. Change over is extremely easy (very few parts and fast adjustments). Machine is sturdy built and silent in operation and maintenance is very low. Three models are available to cover a large range of sizes. Implementation of various coding, inspection and feeding systems for any type of carton, leaflet/booklets and the handling of any pharmaceutical or cosmetics products makes the DYNAMICA cartoner a suitable choice for high speed cartoning projects.
END OF LINE
Finally on display, is the IMA BFB CP18 side loading case-packer incorporating a new concept which makes it particularly suitable for the packaging of individual or bundled cartons/trays into pre-glued RSC cases. The machine is extremely compact (being the product stacking operation performed in front of the main pusher) and accessible, thanks to its cantilever design. The case magazine is horizontal to make for easy loading. Pick-up and forced opening arms with suction cups ensure the case is perfectly square during the product loading operation. Case closure can be done with adhesive tape or with hot-melt glue. The size changeover can be carried out in just a few minutes, with no wrenches required. Fine adjustments can be made thanks to digital indicators. The CP18 is available in two versions (up to 10 or 14 cycles/minute). The CP18 is exhibited in line with the MINIFLEX, to complete change over operations by setting the case on top of a pallet. This is a very economic and compact solution for low/medium speed production lines (up to 5 cases/minute with internal buffer and up to 10 cases/minute with automatic pallet discharge).