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Versatile vial filling line gets an upgrade

Italy's Doppel Farmaceutici has made steady improvements on its twin-lane filling line for a single-dose liquid vitamin. A new filler/plugger/overcapper is the latest arrival.

Product is carried through a series of silicon tubes that are especially suitable for products having a high concentration of glucose.
Product is carried through a series of silicon tubes that are especially suitable for products having a high concentration of glucose.

Recent additions to a high-speed and highly automated glass vial filling line at Doppel Farmaceutici are helping this leading Italian contract manufacturer keep pace with marketplace demand for a popular unit-dose liquid vitamin. The primary container is an especially interesting one because it’s topped by a reservoir cap holding a powdered active ingredient. Consumers remove from the glass vial a white low-density polyethylene overcap, push a red plunger through the bottom of the reservoir cap to release the active ingredient into the liquid, shake the combined contents, remove the reservoir cap, and then drink the mixed contents.


“People really like the reservoir cap concept because they feel they are preparing the product themselves,” says Sabina Gualazzini, production manager at Doppel. “There is a perception of freshness that comes with this delivery method.”


Bormioli supplies the glass vials, the reservoir cap, and the white PP overcap.


Doppel refers to the line as Monodose 1-2. Dedicated to 7-mL vials, it’s actually a dual line whose upstream legs are similar in that both consist of the following:


• a Neri rotary air blower that blows loose any debris in the vials and vacuums it out
• a filler/plugger/overcapper; one leg of the line has a Farmomac F57, the other leg has a Marchesini (www.marchesini.com) ML 618
• a sortation/feeding device for the reservoir cap; each of these caps is filled with 150 g of powder ingredients in Doppel’s Rozzano plant some 52 miles away
• a sortation/feeding device for the overcap that goes over the reservoir cap
• a Neri pressure sensitive labeler that prints variable data on the labels


600 vials/min
These dual legs send vials into a common accumulation table at a combined rate of nearly 600 vials/min. Next in line is a Marchesini cartoner. Either of two packaging formats can be produced:


• When production calls for a retail pack holding 10 vials in a colorfully decorated folding carton, the vials are cartoned on a Marchesini BA 400 sideload cartoner. 48 of these 10-pack cartons are then case packed on a machine from PRB, and the cases are palletized on a MacDue palletizer.
• When production calls for a retail pack holding 30 vials, the Marchesini BA 400 cartoner is fed blank white cartons as opposed to printed ones. These 10-count white cartons are then diverted past the PRB case packer and sent instead to a Marchesini BA 50 sideload cartoner that encloses three white 10-count cartons in a decorated master carton. These master cartons are case packed by hand. One other piece of equipment in the line, located right after the Marchesini BA 400 cartoner, is a Model 01D3 checkweigher from Prisma Industriale.


Both the 10-count cartons and the 30-count master cartons are supplied by Galati.

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