Efficiency is not only about when you produce, but also about when you don’t

In pharmaceutical packaging lines, format changes can take a considerable amount of time, depending on the complexity of the machine and the number of formats handled. This time, combined with potential adjustment errors and the need for corrective actions, can lead to:

• Prolonged machine stoppages
• Loss of productivity
• Increased risk of errors, especially in highly regulated products such as pharmaceuticals

In a context where speed of response to the market is essential, companies can no longer afford such inefficiencies.

IMA SAFE has answered to this increasing need with the new A46 cartoner, that represents a breakthrough for the industry. It’s a medium speed continuous motion horizontal cartoner, addressed specifically to pharmaceutical and nutraceutical purposes. Thanks to its fully automatic size change system with no format parts, it eliminates many of the traditional critical issues. This system leverages advanced positioning drives, which enable precise and rapid adjustments of both product and carton dimensions. By automating these adjustments, the A46 cartoner significantly reduces manual intervention, ensuring consistent quality and minimizing the risk of errors.

How does it work?

• The elimination of format parts simplifies the process
• Automatic adjustments allow seamless switching from one format to another without manual intervention
• The user-friendly interface enables operators to manage the entire process with just a few commands

What are the advantages?

The entire format change can be completed in less than 10 minutes, thanks to a quick setup directly managed via the HMI. During this time, the operator is free to focus on quality checks or on preparing format changes for the rest of the line, instead of performing repetitive adjustments and/or formats replacements. On the cartoner itself, format change operations can be cut by up to 75%, resulting in a significant reduction of downtime and a smoother overall workflow.

Beyond format change: the features that make the difference

While automatic size change is the core innovation, the A46 also brings several distinctive features that further enhance efficiency and usability:

• Compact design: only 3 meters in length, making it one of the most space-saving solutions in its class.
• Accessibility and ergonomics: the carton magazine can be lifted to allow easy internal access, while the ergonomic working height of 1100 mm ensures comfortable operation for the user. In addition, the GUK feeder features front loading at a reduced height compared to standard solutions, making it easier to reach, as well as being fully extractable and removable to maximize accessibility and simplify maintenance.
• Maintenance: all main groups can be removed for quick replacement and maintenance – including even the pusher group – ensuring minimal downtime and fast interventions.
• Format flexibility: capable of handling cartons up to 110 mm in height, as well as larger widths, making it suitable for feeding double blisters/trays stacking.
• High performance: up to 250 cartons per minute.
• A solo-module for accessories: both solutions for booklet and leaflet feeding can be interchanged within a single module, without the need for dedicated space or separate units, further reducing the footprint.

Automatic format change technology, such as that offered by the A46 cartoner, represents the future for companies aiming to optimize their production processes and remain competitive in an increasingly demanding market. But the A46 goes further: compact, ergonomic, and highly flexible, it combines innovation in format change with smart design features that make it a powerful and versatile tool for modern packaging lines. It’s not just about saving time—it’s about transforming downtime into opportunities for growth.

A46
Horizontal continuous motion cartoner with automatic changeover