MediSeal GmbH is a professional manufacturer of pharmaceutical packaging equipment. It has a history of producing blister packaging and cartoning lines, four-side sachet packaging and cartoning production lines. The design and manufacture of equipment meets the current needs of pharmaceutical production. GMP specification requirements. Among them, the company's all-digital servo control blister packaging technology has been highly rated by the industry. Madison full digital servo control technology uses 112400 axis coded precise positioning. Through the bubble-grating detection device, the machine can automatically identify the position deviation of the bubble (the measurement control accuracy is within 0.01mm), and feedback the change amount to the PLC. The controllers and controllers will automatically perform real-time corrections accordingly so as to ensure the precise position of each blister card at each workstation on the entire line. Based on the full-line full-digital servo control, the production line pays more attention to continuously improving the details of each link, and ensures that the production and the products have excellent quality on the basis of high efficiency. Here we may wish to talk about some intriguing details.
* Membrane forming process carefully "care"
In the forming station, a buffer zone is generally designed between the film roll release and the film heating area. The conventional method (shown in FIG. 1) uses a film feed roller and an angle swing bar to control the transport film into the heating area, although This dynamic balance method is sufficient to satisfy the membrane supply during continuous operation of the equipment. However, there must be a certain tension between swinging of the pendulum rod and the film feeding roller, and there is a certain friction between the pendulum rod and the film and static electricity is generated. The adsorption force affects the transport of the film feeding roller to the film, and thus interferes with the quality of the blister during the film heating and shaping process. In order to eliminate external interference, Medici's blister packaging machine uses an ultrasonic sensor instead of the angle pendulum (shown in Figure 2). A certain amount of film is suspended in its own weight between the film feeding roller and film roll release. The amount of suspension can be controlled by an ultrasonic sensor and sent to the heating forming area by the film feeding roller without any external force interference. When the ultrasonic sensor detects the rise of the hanging film position, the film roll is quickly released to supplement the film. Suspension reserves, thus ensuring the forming quality of the blisters.
After the blister is formed, the forming mold is generally opened, and the formed film is separated from the forming mold by its own tension. In this way, the formed film cannot be completely separated from the forming mold due to the change in the physicochemical properties of the film. When the film is pulled, the formed bubble tends to be scratched and damaged by the forming mold. In order to ensure the blister stripping reliability, Medisil uses a vacuum stripping device. The vacuum generation time can be adjusted according to different membranes. When the forming mold is opened, the vacuum controlled by the electronic cam is also opened at the same time, and the formed film and the mold are naturally separated under the combined action of tension and vacuum to prevent the blisters from being scratched.
The high-temperature preheated film and the formed blisters should be said to be in an immature state. Through these details, Medici realized that the preheated film and the formed blisters are free from external interference. During the entire heating and forming process, the film has been Carefully "care" into the next area.
* Sealing pressure "catty"
The air tightness of blister packs is the focus of quality control, controlled by the pressure of the seal and the temperature of the seal. However, the pressure and temperature requirements of different packaging materials are often different. Conventional equipment generally increases the airtightness of the blister board by adjusting the sealing temperature, because the sealing pressure for each time in the production process cannot be known. Causes an excessively high sealing temperature and destroys the drug in the blister, especially in some lyophilized drugs that are sensitive to temperature. Taking this into account, Medcy installed a pressure sensor and displayed the pressure of each seal on the control panel by means of analog-to-digital conversion. The accuracy can reach 0.1 KN. At the same time, the upper and lower limits of the sealing pressure are set, when the sealing pressure Outside of the set range, these sealed blister packs will be rejected. In this way, the sealing pressure of the sealing station can be controlled within a certain range, depending on the optimum combination of pressure and temperature of the different packaging materials.
* Punching classification "each in its place"
There are two types of blisters scrap board: empty board and underfill board. In the general production workshop, the lack of board needs to be recycled, so Medisis designed a separate collection device for the empty board and the missing board. The empty board and the missing board. The guide plates enter the respective recovery boxes, respectively, and the punched waste edges can be directly entered into the waste side boxes, so that the punched and cut objects are in their respective positions, eliminating the time spent on classifying these reject items. Moreover, when the empty board and the missing board pass through the guide board, there is a sensor to check and confirm that the waste board has been removed, so as to prevent the waste board from being brought into the qualified product at the time of high-speed production. In addition, although Medici's blister machines have a high yield, a level sensor is installed on the top of the recovery box. When the reject is filled with the recovery box or waste edge box, the machine will automatically warn the operator Need to remove the box out of the items.
* Mold replacement "embedded" into the hearts of people
The biggest advantage of digital servo is the quick and convenient replacement of molds. The specification data of different products are stored in the computer: all specifications, drawing film length of forming station, sealing station and punching station, setting parameters of camera detection system, waste board Excluding the deposit and the like, the time for the operator to change the specifications and re-adjustment is eliminated - the operator only needs to call the corresponding product specification program, and all the specification parameters can be automatically called from the memory in the machine. At the same time, the replacement of molds, such as forming dies, sealing dies, punching dies, and guide rails, is also simple and convenient for each workstation. Each part is equipped with a special quick locking system for Medics, as long as each mold is embedded in the positioning hole or guide groove of the base. It is then possible to lock the respective quick-locking elements. This method of replacement is both accurate and quick without special tools.
* Remote troubleshooting "Global synchronization"
A modem is configured in the main control cabinet of all Medicilon equipments. When the equipment is accepted, it is necessary to test whether the connection from the German headquarters can be connected with the modem to ensure remote fault diagnosis. In this way, once the equipment has a problem in the program, regardless of the location of the equipment on the earth, through the remote fault diagnosis system, the operating parameters of the equipment can be directly displayed on the diagnostic platform of the Medici Germany factory and data can be entered by entering the advanced password authority. modify. The application of a new generation of digital servo technology is more conducive to remote fault diagnosis. This technology can also realize remote diagnosis of a single servo motor. Engineers can even find the serial number and fault code of the servo motor. Therefore, for the sudden stoppage of failures, this globally synchronized remote diagnosis technology enables the production site to find the cause of the failure in the shortest possible time, reducing unnecessary delays.
* Quality Control "Conviction"
In recent years, the safety of pharmaceutical packaging has been placed in a prominent position. Many pharmaceutical equipment suppliers have paid special attention to testing equipment. However, on-line testing equipment is generally provided by professional testing equipment manufacturers, such as bubble eyelets. Detection, lack of filling board detection, etc., when a problem is detected, send a signal to the PLC to remove the corresponding blister board, but in this way, there will be blind spots in the control of the whole line, such as detecting the external interference or blisters The board is just at a zero point. For this detail, Medicis used the settings to think that every blister card was problematic from the very beginning, and then passed a qualified confirmation value for each detection device, only when all tests passed the qualified value. Confirm that it is a qualified product. This avoids blind spots in the entire line control.
In the era of escalating pharmaceutical industry specifications and the emergence of new technologies, Medicis Corporation has also been pursuing technological innovation while also pursuing and refining the details of each link, as details often play a role in uncertainty. The quality of the equipment not only comes from excellent craftsmanship and stable functions, but also from the details of those years of experience that have been set aside.
(The author of this article comes from Medicis Co., Ltd. Shanghai Representative Office)
Source of information: pack.cn