Overcoming challenges in filling for microtubes, cannulas, and small applicators

The manufacturing cycle of pharmaceutical and veterinary products is characterized by the need for precision and efficiency. However, when it comes to filling very small and delicate items, such as microtubes, cannulas, and small applicators, maintaining these standards can be extremely challenging. These small articles, often shipped bulk from manufacturers, are inherently difficult to handle and fill, leading to inefficiencies and potential quality issues.

Delivering consistent quality in small sizes

Traditional tube filling machines often fall short when handling microtubes, cannulas, and small applicators. These components are small, fragile, and typically arrive in bulk, presenting unique challenges in sorting and orientation before reaching the filling stage. Conventional feeding systems, designed for larger tubes, struggle to accommodate these requirements, leading to inefficiencies and potential damage.

Precision in filling is another critical concern. Once these small items reach the filling stage, the challenges persist. Even the slightest deviation during dosing can lead to quality control issues, particularly for products where dosage accuracy is paramount. The complexity increases further when dealing with extremely low dosages and narrow applicator openings, which require specialized equipment to maintain exceptional accuracy. At the same time, coding and tracking these small items introduces additional hurdles. Limited printing surfaces make codes difficult to read by sensors, and misreading defective products can disrupt the entire process.

Despite the need for such precision, manufacturers cannot afford compromises on production timing. High throughput remains essential even when dealing with small sizes. Successfully navigating these challenges requires innovative solutions that ensure consistent quality while meeting the demanding pace of modern production environments.

Customization as the key solution

While precision and care are inherent to handling microtubes, cannulas, and applicators, optimizing processes and reducing inefficiencies is possible through customization. Extensive experience in developing tailored solutions is crucial in overcoming these challenges.

At the feeding stage, vibratory and centrifugal systems play a vital role in ensuring smooth sorting and seamless integration into the production line. Specialized systems can be developed to handle even the most delicate and irregularly shaped components with care, preventing jams and inconsistencies that could disrupt production. For example, in the case of small and delicate products, the items can be transported in godets between the feeding system and the filling process, ensuring stability and protection before they reach the dosing stage.

Customization is equally essential at the filling stage. Specialized micro-metering pumps must be designed to dose even the smallest product volumes with the highest accuracy, maintaining strict quality standards. Our solutions are developed through in-depth analysis of liquid or cream viscosity and volume, incorporating advanced filling technologies that guarantee precision, even for complex formulations.

Equally important is the role of high-accuracy sensors during the inspection phase. These sensors ensure seamless traceability and integrate into quality control processes, upholding the highest standards while minimizing the risk of inaccuracies throughout the manufacturing line.

Having this expertise does not only mean meeting quality standards—it also ensures that customization does not come at the expense of production efficiency. IMA Safe Comadis have a long history of developing tailor-made solutions on these products, balancing precision with efficiency. These quality standards are guaranteed by a dedicated team that anticipates the potential challenges in these production lines, and optimizes the solutions accordingly delivering consistent quality, even in small sizes.

Special C1290 for applicators – Special C1290 for VET tubes