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Send to KindleAenova partners with packaging supplier to address global pharmaceutical market changes
A Noack 960R blister-packaging line with rotary sealing that provides a maximum output of 600 blisters/min is the most recent addition. It was installed in August 2012. The system includes Romaco’s Promatic PC 4250 continuous-motion cartoner and offers an end-to-end solution for packaging tablets, capsules, and oblongs. The new line is the result of the most recent development cooperation between Aenova and Romaco Noack.
Development cooperation generates new impetus
The cooperation between the two companies focused on ensuring that the blister line was easy to use and on shortening the changeover and cleaning times. The aim was to enable one employee to change the product and the packaging within a very short period.
A systematic approach was taken to achieving this objective, using a blister line model from the same family as the prototype. The Noack 930, which in principle is identical, has been in operation at Aenova since the summer of 2011. All the processes in this line were tested step-by-step under real production conditions and their potential for development was evaluated. The results of the tests were incorporated into the design of the new blister line.
“We were particularly impressed by Romaco’s single-minded approach to developing and improving its blister packaging systems,” says Reiser. “The new Noack 960R is highly reliable and meets all the technical requirements that we specified during the planning process.”
Dual ‘QuickFeed’ system
The weekly production volume of the new blister line is between 15 and 20 batches. It can be used, among other things, for packaging multi-phase products, where there is a difference between the morning and the evening dose, for example. These products are generally supplied in combined blisters. For this purpose, Romaco Noack has equipped the new line with two feed units, which allow the blisters to be filled with two different products.
During product changes, the patented “QuickFeed” technology makes it possible to remove the entire feed unit without tools in a matter of seconds. An airglide system enables the entire feed unit to be transferred to a special transport truck and moved to a specially equipped assembly room, where the format parts are removed, all the components are
cleaned and the new tools are fitted. During the changeover and cleaning period, production can continue with the second QuickFeed unit.
“It is very important to us that our internal logistics enable us to fully exploit the potential of the QuickFeed technology,” explains Reiser. “We are focusing on implementing a modern lean management system and Romaco Noack’s systems are helping us to make full use of our capacity.”
Continuous process control
A further important requirement for efficient primary and secondary packaging processes is reproducible process parameters. All the production data is entered and accessed via the user-friendly operating terminal of the blister line. Processes that have been saved can be repeated at any time and current batch data can be checked quickly.
A total of 17 servo drives control the process of packaging the products into blisters and cartons. For example, the QuickAdjust station control systems are responsible for the coding, perforating, and die-cutting processes. The servo drives automatically compensate for variations in foil characteristics.
A servo-controlled robotic transfer station moves the blisters to the cartoner.
A lifting and turning unit removes the packages from the die-cutting station and a vacuum conveyor is used to transfer them to the stacking station where they are placed directly into the bucket chain of the cartoner. The high level of automation results in reliable processes and excellent product quality. “We have been impressed by the outstanding efficiency of the entire Noack 960R blister packaging line, together with the reduction in downtime and the very good price/performance ratio,” concludes Reiser.
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