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PRE-FILLED SYRINGE PACKAGING LINE
An extensive choice of integrated machines to create a highly customised solution with significant automation, delivering exactly what is wanted.
LIMITLESS CONFIGURATION
With so much flexibility, the choice lies with the customer.
Speeds, operations, configurations, with in-line sampling possibilities that avoid downtime, a syringe labelling, assembly and packaging line that leaves nothing to chance.
Only closely integrated equipment and technologies allow for such free customisation.
A line featuring the most flexible handling and assembly solutions available on the market starts with a choice of automatic or manual depalletizing that proceeds with D-NEST, the syringe denesting machine. Highlight of the line, MODULA offers plunger rod insertion, labelling and backstop assembly combined as required, upgradable from 1 to all 3 operations, handling all pre-filled syringe formats. Deep draw thermoforming solutions for high and low-speed packaging, alternatively the latest medium-speed RED250, making its debut at ACHEMA, handle any type of parenteral product and are compatible with accessory feeding modules for needles, spoons or booklets, ensuring a wide choice of product/accessory positioning variety on the tray. All three adapt to in-line cartoners, such as the new A46 which handles 250 ctn/min. and features an automatic size changeover which is performed in less than 10 minutes. End-of-line case-packing steps with fully automatic side or top loading capabilities and RP palletizing solutions can be stand-alone or fully integrated for a complete line.
The synergy between IMA Life, IMA Safe and IMA BFB ensures a complete range of syringe assembling and packaging machines like never before. Precision, safety, versatility and high production performance are just a few of the advantages that your one-stop-shop supplier can guarantee from filling to end-of-line.
Discover our Machines
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[seo_title] => High-speed decontamination tunnel • NEBULA • IMA Group
[seo_description] => Discover NEBULA, the high-speed decontamination tunnel by IMA Group. It sterilizes tubs and trays as they enter and transit isolated production lines.
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[tile_speed] => Up to six tubs or trays/minute
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[overview] => NEBULA is a high-speed decontamination tunnel that sterilises tubs and trays containing RTU material as they enter and transit isolated production lines in continuous mode.
Adopting an unprecedented approach to ensuring 100% sterility of RTU material as it enters and transits isolated production lines, NEBULA is a high-speed decontamination tunnel which integrates seamlessly with IMA LIFE aseptic fill-finish lines. 6-log decontamination is achieved over the entire external packaging surface using aerodynamic containment of highly concentrated Vapour Phase Hydrogen Peroxide (HC-VPHP), while material crosses the tunnel in a matter of seconds. This allows for continuous, high-speed tub introduction, up to six per minute.
This is the ultimate method in the category of surface decontamination technologies, with marked differences compared to the alternative NTT (No-Touch-Transfer) technology or other decontamination solutions.
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[technical_data] => | NEBULA TECHNICAL DATA |
|
| Features | Dimensions |
| Decontamination tunnel dimensions (cleanroom) | 3.7 m (L) x 0.9 m (W) x 1.5 (H) + Inlet/outlet piping up to the ceiling |
| Power supply & ventilation skid dimensions (technical area) | 2.3 m (L) x 1.2 m (W) x 2.8 m (H) |
| AHU Dimensions (Technical Area) | 2.0 m (L) x 0.8 (W) x 2 m (H) |
| Cabinet H2O2 solutions (cleanroom/technical area) | 1.2 m (L) x 0.5 m (W) x 1.6 m (H) |
| Ready-To-Use tub/trays | 3-4” Tubs (standard Nebula), 6” tubs, vial trays (to be requested) |
| Outlet H2O2 catalyser | included |
| Output | Up to 6 RTU/min (max speed @ 30sec 6-log decontamination time) |
| Expected 35% H2O2 solution consumption in production | 6 l/hr |
| H2O2 Storage | 2x20L tank – 35% aqueous hydrogen peroxide solution high purity – low residues |
| Requested utilities |
Ventilation inlet airflow: 450 m3/h from technical area |
Responding to the GMP Annex 1 notes, whereby risks linked to sterility assurance must be minimised during material transfer and supported by high-capability transfer technology, NEBULA accomplishes what no other solution has done before.
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NEBULA
Responding to the GMP Annex 1 notes, whereby risks linked to sterility assurance must be minimised during material transfer and supported by high-capability transfer technology, NEBULA accomplishes what no other solution has done before.
Hyperspeed decontamination technology
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[tag_line] => INJECTA 36. Single detection, single rejection.
[overview] => The use of advanced robotic-driven manipulations versus conventional handling systems actually improves product quality and manufacturing efficiency.
INJECTA 36 handles pre-sterilised Ready-To-Use containers (syringes, vials or pre-capped cartridges) pre-arranged in tubs, allowing high process flexibility and adaptability.
Specialised robots perform all handling activities with no glass-to glass contact and without operator intervention. The result is “less time” spent validating aseptic conditions and superior agility for multi-product manufacturing.
The highest accuracy and safety in plunger presence detection and single non-conformity rejection are ensured by DETECTA, IMA Life’s ultimate high-speed inspection unit, which can be integrated downstream of INJECTA 36.
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[technical_data] => | FEATURES | INJECTA FAMILY | ||
| INJECTA 36 | INJECTA 10 | INJECTA 6 | |
| Automation | Fully robotic automated | Fully robotic automated | Fully robotic automated |
| Footprint (mm) | 3,400 x 2,050 x 2,080 [L x W x H] | 7,200 x 4,500 x 2,080 [L x W x H] | 6,100 x 3,600 x 2,080 [L x W x H] |
| In-Process Control | 100% | 100% at full speed | 100% at full speed |
| RTU vial dimensions | Ø 16 – 42.4 mm | Ø 16 – 42.4 mm | Ø 16 – 42.4 mm |
| Vial output | up to 18,000 pcs/h | up to 12,000 pcs/h | up to 4,800 pcs/h |
| RTU syringe dimensions | 0.5 – 20 ml | 0.5 – 50 ml | 0.5 – 50 ml |
| Syringe output | up to 36,000 pcs/h | up to 12,000 pcs/h | up to 4,000 pcs/h |
| RTU cartridge dimensions | 1 – 20 ml | 1 – 20 ml | 1 – 20 ml |
| Cartridge output | up to 18,000 pcs/h | up to 10,800 pcs/h | up to 3,600 pcs/h |
| Suitable for high-potent | Yes | Yes | Yes |
| Loading from depyrogenation tunnel | No | Yes | Yes |
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INJECTA 36 is a fine-tuned solution to enhance aseptic fill-finish capabilities and maximise processing line performance. Handling up to 36,000 RTU components per hour, in particular syringes, the system adopts innovative robotic and automation technologies.
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Introducing an innovative solution for 100% In-Process Control and check-weighing, INJECTA 36 consolidates IMA Life as a key player in the Ready-To-Use segment for automatic filling & closing machines to maximise production performance.
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INJECTA 36
INJECTA 36 is a fine-tuned solution to enhance aseptic fill-finish capabilities and maximise processing line performance. Handling up to 36,000 RTU components per hour, in particular syringes, the system adopts innovative robotic and automation technologies.
INJECTA 36. Single detection, single rejection.
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[overview] => The ROBOTIC D-NEST module works for both upstream and downstream processing.
In the upstream process, its flexible handling system allows for precise removal of the RTU vial from the nest. This is followed by individual component filling, check-weighing, stoppering and ultimately the component is placed back into the nest or transferred via a conveyor belt for process completion.
As a downstream handling solution, the ROBOTIC D-NEST module removes the filled and stoppered RTU vials from the nest and transfers them in single track downstream for vial capping or automatic vial loading in the case of lyo products. Containers are always safely positioned on the gentle container transport belt.
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[cover_focus_content] => Fully robotised denesting of sterile Ready-To-Use vials performed by specially designed six-axis robots. ROBOTIC D-NEST accomplishes all critical operations in aseptic environments.
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ROBOTIC D-NEST
Fully robotised denesting of sterile Ready-To-Use vials performed by specially designed six-axis robots. ROBOTIC D-NEST accomplishes all critical operations in aseptic environments.
Denesting robotics where required
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[cover_focus_content] => C360 is the IMA Safe’s latest trends setting a thermoformer designed for deep draw packaging with a superior flexibility in terms of production applications and modularity.
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[tag_line] => With all 360° in mind
[overview] => C360 is the most compact deep draw thermoforming machines in their range keeping the maximum customisation that exactly meets the customer’s production requirements.
All this is possible thanks to the use of the IMA Safe technology which has developed robotized systems applied in the most critical areas: the product feeding area & the connection to the cartoner.
This machine is not only highly productive but also extremely efficient, size changeover operations are rapid thanks to a reduced number of size parts.
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This system is able to handle sustainable plastic materials.
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[technical_data] => | Model | C260 | C360 |
| Production output |
up to 800 1-2 ml DIN ampoules/minute up to 400 1 ml syringes/minute |
600-1000 1-2 ml DIN ampoules/minute up to 600 1 ml DIN syringes/minute |
| Forming depth | 3 mm – 40 mm | 3 mm – 40 mm |
| CARTONERS | |
| X Series | up to 120 cartons/min.* |
| FLEXA Series | up to 150 cartons/min.* |
| DYNAMICA Series | up to 250 cartons/min.* |
*Different customizations on demand
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C360
Deep draw thermoforming machines.
C360 is the IMA Safe’s latest trends setting a thermoformer designed for deep draw packaging with a superior flexibility in terms of production applications and modularity.
With all 360° in mind
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[cover_descriptor] => Deep draw thermoformer
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[cover_focus_content] => The new integrated RED250 deep draw thermoforming and cartoning line is a compact solution for medium-speed production of small batches requiring frequent format changes.
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[overview] => Thanks to the robotic handling system, RED250 allows careful and precise manipulation of any type of product, introducing it into the tray with a wide range of possible configurations.
The new integrated A46 cartoning module can perform a complete automatic size changeover in just 10 minutes, allowing the operator to carry out the other operations necessary for the preparation of the next batch.
In the face of increasingly demanding production needs, the new line represents an agile solution ensuring precision and performance.
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[sustainability] => Bio-degradable tray Project
IMA offers a complete range of deep thermoforming machines from low to high speed.
All of them are designed with the environment in mind. Our well established technologies have been thought once again for the best handling of new generation materials such as the bio-degradable PLA. We keep the same performance, the same quality, with a new purposes: our Planet.
Applicable to No one is forgotten: new applications are suitable for retrofitting on existing C260, C360 and C102 with just small adjustments in the forming area.
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[technical_data] => | MAX PRODUCTION OUTPUT | |||||
| TRAYS | CARTONS | FORMING DEPTH | LIDDING MATERIALS | LIDDING MATERIALS | CARTON DIMENSION |
|
800 1-2 ml DIN 400 1 ml DIN syringe/min |
250 ctn/min | 3 mm – 40 mm | ALU, PP, PVC, PVC/PVDC, PVC/ACLAR®, PET, PETG, PS and others | ALU-HARD, ALU-SOFT, ALU/PAPER, ALU/ POLYESTER, PP, TYVEK® and others |
A: 35-95 |
RED250
The new integrated RED250 deep draw thermoforming and cartoning line is a compact solution for medium-speed production of small batches requiring frequent format changes.
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[cover_descriptor] => Continuous motion cartoner
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[cover_focus_content] => DYNAMICA Series multipurpose continuous motion cartoner is available in different versions, according to the product specifications, carton dimension sizes and speed. It grants the maximum versatility in terms of applications, infeed systems and carton sizes
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[tag_line] => Beyond the limit of the maximum flexibility
[overview] => Flexibility as key feature: this Series offers the widest range of products to be packed, carton dimension range and applications. Moreover, DYNAMICA S version is able to combine both the continuous and the intermittent motion depending on the product fed.
The ergonomics, in terms of carton magazine, product flow and leaflet folding unit heights, is maximum. Last but not least, DYNAMICA is also compact but at the same time easy to manage and intuitive to set up.
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This system allows the use of recycled cardboards.
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[highlight] => Multi-purpose.
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[highlight] => Feeding systems: wide range of solutions to pack different products.
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[highlight] => Very wide cartons sizes range.
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[highlight] => IMA Safe Roll-One, leaflet folding unit.
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[highlight] => Ergonomic design.
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[content] => Cost effective and flexible feeding systems are available at IMA Safe, which offer a wide range of solutions for both pharma and extra pharma fields.
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[technical_data] => | TECHNICAL DATA DYNAMICA | ||||
| Width (A) | Height (B) | Lenght (H) | Production output | |
| DYNAMICA L | min 25 – 130 max | min 12 – 90 max | min 65 – 200 max | Up to 250 cartons/min. |
| DYNAMICA E | min 30 – 90 max | min 15 – 65 max | min 100 – 250 max | Up to 300 cartons/min. |
| DYNAMICA SLEEVE* | min 48 – 90 max | min 8 – 15 max | min 65 – 106 max | Up to 350 cartons/min. |
| DYNAMICA S | min 25 – 95 max | min 12 – 90 max | min 65 – 200 max | Up to 350 cartons/min. |
| DYNAMICA V | min 25 – 95 max | min 12 – 90 max | min 65 – 150 max | Up to 400 cartons/min. |
*Version for carton sleeve style
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DYNAMICA
Continuous motion cartoner.
DYNAMICA Series multipurpose continuous motion cartoner is available in different versions, according to the product specifications, carton dimension sizes and speed. It grants the maximum versatility in terms of applications, infeed systems and carton sizes.
Beyond the limit of the maximum flexibility
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[tile_description] => SIDE LOADING CASE PACKING MACHINE. Medium speed case packer designed to handle the widest range of products and materials used in the pharmaceutical industry.
[tile_speed] => 10 cycles/min.
[cover_macro] => 14803
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[cover_name] => CPH2
[cover_descriptor] => Side loading case packing machine
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[cover_focus_content] => Medium speed case packer designed to handle the widest range of products and materials used in pharmaceutical, with maximum ease of use and total control of the packaging process
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[tag_line] => Fit for the future
[overview] => Fully automatic side loading case packer designed to satisfy all of your current and future case packing requirements.
The machine has been built to maximize efficiency and ease of use in an ever increasingly demanding work place, to guarantee complete line clearance and to ensure total access to all modules.
The CPH2 is designed to ensure total control throughout all stages of the serialization process.
Flexibility, maximum efficiency, total access and total control make the CPH2 a casepacker of new generation.
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[highlight] => The new 830 mm high case magazine ensures easy loading of cases. Correct case feeding to the
picking area is guaranteed by a bottom driven belt.
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[highlight] => Designed to ensure total access to all machine modules: all parts of the machines can be reached from the operator’s side.
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[highlight] => Forced opening of the case through two arms allows reliable operations even in case of square shippers or low quality material.
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[highlight] => Simple design servo driven stacking unit with easy access to cartons collating area. Stacking operation is carried out right in front of the erected case.
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[highlight] => A servo driven movable hopper follows the cartons collation up into the case and guarantees security of case content.
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[highlight] => Quick tool-free size changeover with limited amount of adjustments. Fast release system by means of clip switches (on/off): no parts need to be unscrewed with keys.
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[technical_data] => | CPH2 TECHNICAL DATA | |||
| Case dimensions | A | B | C |
| Min. | 220 | 100 | 90 |
| Max. | 600 | 400 | 400 |
| Product dimensions | a | b | c |
| Min. | 25 | 22 | 60 |
| Max. | 590 | 70/150 | 220 |
| Speed | 10 cases/min. | ||
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CPH2 is available in different palletizer-integrated versions, according to the output required:
CPH2-RP2
With automatic replacement of the full pallet and case buffering during pallet replacement or with two pallet stations; once one pallet is complete, the robot starts loading the second pallet
CPH2-RP4
With 4 pallet stations for greater autonomy. When the pallet is complete, the automatic transport moves the pallet to the exit area and replaces it with an empty one.
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CPH2
SIDE LOADING CASE PACKING MACHINE. Medium speed case packer designed to handle the widest range of products and materials used in the pharmaceutical industry.
Fit for the future
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[cover_name] => RP2/RP4
[cover_descriptor] => Stand alone or integrated palletizing
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[cover_focus_content] => Reduced dimensions of the palletizing section and flexible palletizing options, in line with real market needs; these aspects characterize the RP2/RP4 palletizers, equipped with a 6-axis robot capable of absorbing and working at high speed.
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[tag_line] => Smart technology for different products and tasks.
[overview] => Built to deliver maximum productivity and efficiency, these latest-generation palletizing solutions offer exceptional flexibility. Based around a 6-axis robot which picks up incoming cases, ink-jet printing and labelling or weighing them, everything is carried out efficiently.
Cases are then placed on the pallet according to pre-set patterns memorised by the operator. Modular design allows for customization of the palletizing section, whose dimensions are kept to a minimum.
RP2/RP4 palletizers are conceived to be stand alone or easily integrated with case packers thanks to their quick plug-in connection.
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[highlight] => Modular design for efficient use of available space. The modules can be installed in a way that overcomes restrictions presented by existing facility layout. and design.
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[highlight] => Equipped with their own electrical cabinet they can be easily integrated with any case packing solution.
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[highlight] => Flexibility in terms of handling various sizes, shapes and weights: these systems can treat single or multiple cases, trays, bags and groups of bottles even at high speed.
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[highlight] => Enhanced performance thank to fast and simple format changeovers and reduced maintenance operations.
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[highlight] => Flexible palletizing options: from 1 to 4 stations for pallet transport and palletization.
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[technical_data] => | TECHNICAL DATA | |||
| Product dimensions | A | B | C |
| Min. | 800 | 1200 | 1400 |
| Max. | 1000 | 1200 | 1400 |
| Max. speed | up to 10 cycles/min. | ||
RP2
Automatic palletizer with single palletization station suitable for handling RSC cases or naked bundles, picked up by means of a six axes manipulator. When pallet is complete, the robot places the cases on the buffer area, giving the operator time to unload the full pallet while the machine is working.
RP7
Automatic and extremely flexible palletizer with double palletization stations suitable for handling RSC cases or naked bundles, loaded by means of a six axes manipulator. When the pallet is complete, the automatic pallet transport moves the complete pallet to the waiting area on exit and replaces it with a new one, ready to be loaded. Operator removes the full pallet and the machine keeps on working at the same time.
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Automatic palletizer with single palletization station suitable for handling RSC cases or naked bundles, picked up by means of a six axes manipulator. When pallet is complete, the robot places the cases on the buffer area, giving the operator time to unload the full pallet while the machine is working.
RP4
Automatic and extremely flexible palletizer with double palletization stations suitable for handling RSC cases or naked bundles, loaded by means of a six axes manipulator. When the pallet is complete, the automatic pallet transport moves the complete pallet to the waiting area on exit and replaces it with a new one, ready to be loaded. Operator removes the full pallet and the machine keeps on working at the same time.
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RP2/RP4
PALLETIZER. Speed, reduced dimensions of the palletizing area and flexible palletizing options, in line with real market needs: these aspects characterize the RP2/RP4 palletizers, equipped with a 6-axis robot capable of absorbing and working at high speeds.
Smart technology for different products and tasks.