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Virtual packaging machinery training offers interactive experience

Pharmaceutical packaging workers can practice setup, changeover, and functions customized for specific machines with computer-animated tools.

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In the “real world,” an experienced machine operator may train a new hire how to operate, change over, and/or maintain packaging equipment. That may be the way it’s “always been done,” but it may be inefficient and inconsistent.

A more standardized training approach that could address the longstanding concerns of how to replace the knowledge of aging and retiring packaging veterans exists in the form of computerized “virtual training” programs for manufacturing and packaging equipment that involves animated and interactive videos and reference materials from Product Animations, Inc. (PAI).

The company’s Productivity Improvement Tools aim to help manufacturers by reducing preventable errors and damages to machinery from improper assembly, by improving safety and compliance, diminishing changeover scrap, and by boosting the consistency of operations.

Charles Roberson, PAI’s president and founder, explains that the tools can be developed to provide customized training on virtually any packaging or processing equipment (primarily solid-dose blending, milling, fluid-bed, drying, granulation, coating, tablet-compression or coating machines).

Up to this point, animation has been used most frequently for virtual training on thermoformers, pouch fillers, unscramblers, tube fillers, cappers, labelers, cartoners, overwrappers, and case packers.

“Almost all of our business has been in the pharmaceutical area because of the value proposition,” says Roberson. “When you have a machine that’s creating tablets that have a value of $10 apiece, and you have a machine that’s producing 10,000 a minute, you really are interested in keeping that machine running.” The investment for virtual training wouldn’t make as much sense for a lower-priced product. 

End users and suppliers

A visit to PAI’s Web site reveals that its list of clients includes both end-user firms such as Pfizer, Lilly, GSK, McNeil, Merck, and Wyeth, while Oystar Jones, Uhlmann, Omega, and Weiler are among the packaging machinery suppliers with which PAI has worked to create virtual training programs.

Roberson explains that PAI approaches equipment vendors in an effort to sell the virtual tools to end-user customers. One of PAI’s business strategies is to offer machine makers a small percentage of the sales. “If they say yes to developing a program, and they sell it to their clients, we give the [equipment supplier] a larger percentage of the sale,” he says. These can be on a single machine or an entire packaging or processing line.

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