COMBO FEEDER Handbook
Page 1
COMBO FEEDER
TABLE OF CONTENTS
INTRODUCTION............................................................................................... 2
1- ECONOMICAL JUSTIFICATION OF COMBO FEEDER ..................... 2 1-1- INCREASED PRODUCTIVITY........................................................................... 2 1-2- INCREASED PRODUCTION CAPACITY ............................................................. 4 1-3- GREATER OPPORTUNITY FOR ALTERNATIVE DISTRIBUTION FORMATS........... 4 1-4- INCREASED QUALITY.................................................................................... 4 1-5- SAFETY IMPROVEMENT ................................................................................ 4 1-6- VERSATILE INVESTMENT FOR OLD OR NEW BLISTER LINE ............................. 4 1-7- IMPROVED APPEARANCE .............................................................................. 5
2-TECHNICAL DETAILS................................................................................. 6 2-1- FUNDAMENTALS .......................................................................................... 6 2-2- COMBO FEEDER BASE PLATE........................................................................ 7 2-3- FEEDING..................................................................................................... 10 2-4- VARIOUS CONFIGURATIONS........................................................................ 12
2-4-1- DUO configuration............................................................................. 12 2-4-2-TRIO configuration ............................................................................. 13
2-5-DISTRIBUTION FORMATS ............................................................................. 13 2-5-1- Distribution by chute .......................................................................... 14 2-5-2- Distribution by box ............................................................................. 16 2-5-3- Distribution by vibrating chute .......................................................... 18 2-5-4- Rotary distribution.............................................................................. 20 2-5-5- Distribution by feeding roll (drum feeder) ......................................... 21 2-5-6- Distribution by tubes .......................................................................... 22
2-6-ADDITIONAL DEVICES ................................................................................ 23 2-6-1- Combo device +.................................................................................. 23 2-6-2- Mobile Carriage ................................................................................. 24
3- EXAMPLES OF CURRENT INSTALLATIONS..................................... 25
CONCLUSION.................................................................................................. 26
Page 2
COMBO FEEDER
INTRODUCTION Since the early 2000s, pharmaceutical companies have experienced significant changes in the manufacturing of their product(s):
• Quality requirements continue to gain importance. • The average production batch size has been reduced, especially with the
increase of generics. • Improving productivity has become a strategic objective in order to reduce
industrial costs.
However, the third constraint is often inconsistent with the first two, making traditional solutions generally unsuitable. The Combo Feeder was developed by the Packaging Team at EPMO to provide a solution to overcome these obstacles:
• By accommodating several types of distribution (chute, vibrating chute, universal brush box, rotary feeder, tube feeder and feeding roll) which makes it possible to choose the best method for each product.
• By reducing the cost of investing in a new blister line. • By significantly minimizing the set-up time of the blister line. • By reducing the amount of time needed to clean and change the distribution
format. • By limiting the risks of cross contamination. • By revitalizing existing blister machines. • By increasing the versatility of blister lines utilizing different makes and models.
1- ECONOMICAL JUSTIFICATION OF COMBO FEEDER
1-1- Increased productivity The primary justification for the Combo Feeder is an increase in the productivity of the blister line.
Increased productivity is attributed to: • Faster changeover of distribution formats. Time will be reduced from a few
hours (in the event of changing a base plate) to a few minutes. Additionally, vacuuming and cleaning the blister line requires less time.
• Increased blister line production rates within the framework of the Combo Feeder. Accurate adjustments are quickly reproducible. The digital interface makes it possible to quickly restore settings from previous runs.
• The simplicity of adjustments in the Y and Z axis. Adjustments can be made during production to optimize the run rate depending on environmental conditions or the evolution of tablets within the same batch (dimensions, surface quality).
Page 3
COMBO FEEDER
The graph below, inspired from a real case, illustrates these productivity increases. With a constant type of distribution (chute), the Combo Feeder is more productive than a traditional feeder considering:
• On the 1st batch (172800 blisters), the production time and labor utilization were reduced by 11.5%.
• On the following batches, the production time and labor utilization were reduced by 3.0%.
Change of format and increase of speed IMAC60
Gain1Change
of format
Gain 3 Speed
stabilized Gain 2
Increase of speed
0%10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 1 2 3 4 5 6 7 8 9Hours
10 11 12 13 14 15 16 17
Chute without Combo
Chute with Combo Mac
hine
spe
ed %
These gains in productivity using a "constant distribution type" are in addition to the increased productivity related to utilizing the optimal distribution format. Indeed, the Combo Feeder makes it possible to use several different distribution formats on the same base so that the best compromise of cost/performance can be chosen, without being overly penalized by the cost of investment (new feeder cost) or by the cost of exploitation (labor cost for feeder change). This is true because the selected Combo Feeder base will support all necessary distribution formats which are quickly changed-over by hand.
Page 4
COMBO FEEDER
1-2- Increased production capacity The improved productivity also increases the output of the blister line.
This is a significant point in the case of fully utilized equipment. With the purchase of a Combo Feeder, it is possible to postpone investment in a new line.
1-3- Greater opportunity for alternative distribution formats In general, the packaging department of pharmaceutical companies has a heterogeneous inventory of blister machines (various makes and models). The feeders are then dedicated to a specific model.
However, the Combo Feeder makes it possible to move feeder formats compatible with one blister machine to another, depending how the tablets are set-up.
1-4- Increased quality For cleaning, the formats are dismounted, disassembled and washed. The remaining Combo Feeder base plate has no exposed openings where tablets or dust can collect, which is an important factor in reducing cross contamination risk.
Moreover, the accessibility of the equipment allows for convenient cleaning and removal of the collected dust.
1-5- Safety improvement The base plates, which are in general heavy equipment, have been secured with a safety stop to ensure safe handling of the equipment and increased protection for the users.
1-6- Versatile investment for old or new blister line The Combo device can be acquired to temporarily improve the performance of an existing line, and then can be transferred if a new line is purchased.
This option offers several advantages:
• When a new blister line is set-up, only the forming, sealing, and cutting functions must be modified.
• The costs of the Combo Feeder can be notably lower than a device sold by the machine manufacturer.
Page 5
COMBO FEEDER
1-7- Improved appearance Although not easily quantifiable, it is undeniable that the replacement of the traditional feeders with a Combo Feeder improves the appearance of the line of production. The following comparison, displaying before and after photographs, demonstrates this advantage.
Before
After
Before After
Page 6
COMBO FEEDER
2-TECHNICAL DETAILS
2-1- Fundamentals
The Combo Feeder is composed of 3 distinct parts:
A base support that contains the user interface and motors.
A vertically adjustable feed hopper to direct the flow of products.
Parts for the distribution formats which are interchangeable and selected based on the nature and the geometry of the product as well as the presentation of the blister.
Page 7
COMBO FEEDER
2-2- Combo Feeder base plate The Combo Feeder is permanently installed on the blister machine in place of the original feeder equipment. It provides:
• support for the format parts • an adjustable base for the format parts • enclosure of the transmission and drive • the user interface • removal of aspirated dust • support for the feed hopper
Support for the format parts
Adjustments
The base has knobs for vertical (Y-axis) and lateral (Z-axis) adjustment of the feeder output relative to the foil
Page 8
COMBO FEEDER
Transmission and drive
Touch Screen User Interface
Touch screen technology presents many advantages :
• automatic features for beginning and completing blister runs
• records feeder adjustments for each product
• easily accessible tutorial • security using passwords
OR
Analog User Interface
A line of switches and potentiometers to control each mechanism An indicator for tension, a switch for the choice of the distribution type, and a switch for manual or automatic operation
Page 9
COMBO FEEDER
Dust Collection
Collection trays are positioned under the guide rails and feeder parts, where necessary. A vacuum can be connected to the Combo Feeder via a series of valves to aspirate dust.
Support for the feed hopper
Page 10
COMBO FEEDER
2-3- Feeding Feeding begins by transferring the tablets into a hopper. They then exit the hopper via a vibrating rail. Finally, they fall into a chute and arrive directly at the level of the distribution. The hopper is designed for easy handling. Tablet output can be regulated using the vertical adjustment on the hopper. It also has a gate to block tablet flow during format changes. The routing rail has small openings to expel dust to a chute where it is aspirated.
Hopper
Vertical height adjustment
Vibrating routing rail A screen under the rail is used to remove dust
The rail is assembled on a dovetail for fast assembly and dismantling
Page 11
COMBO FEEDER
Chute for collecting dust
The tray collects dust for removal
Leveling and Clearing Brushes
The leveling brush lays down tablets so that they are properly positioned in the pocket The clearing brush removes extra tablets from the webbing to prevent loose tablets from entering the blister machine
Page 12
COMBO FEEDER
2-4- Various configurations Several different configurations of the Combo Feeder are available. Model selection is based upon the number and the type of distribution formats likely to be used.
Distribution format selection is dependent upon the shapes and types of all the products that are to be packaged and the required speed of the blister line. The following are general guidelines for distribution format selection: - A brush box is suitable for convex tablets to strongly convex round tablets. - A chute is suitable for easily flowing tablets. - A vibrating chute is used for tablets not suitable for a regular chute because of
shingling effect, such as oval tablets. - A rotary feeder is used for high speed requirements. - A tube feeder is used for high speed intermittent motion blister machines. - A feeding roll is used for cold form blisters (ALU/ALU) or specific feeding
requirements such as pockets oriented perpendicularly to the movement of the webbing.
Additionally, a mobile carriage has been developed for the Combo Feeder. This option gives the Combo Feeder the capability of running the brush box, chute and vibrating chute distribution formats on an intermittent motion blister machine. More information about the mobile carriage solution is available in section 2-6-2.
An appropriate configuration must be selected according to the products to be packaged on the blister line. Project engineers will work with you to determine the optimal solution for your blister line. 2-4-1- DUO configuration
DUO configuration accommodates two distribution formats. Chute Box Vibrating
Chute Rotary Tubes Feeding Roll
(Drum Feeder) DUO-1 X X DUO-2 X X DUO-3 X X DUO-4 X X DUO-5 X X DUO-6 X X Etc…
Page 13
COMBO FEEDER
2-4-2-TRIO configuration
Trio configuration, alternatively, accommodates three distribution formats. Chute Box Vibrating
chute Rotary Tubes Feeding Roll
(Drum Feeder) TRIO-1 X X X TRIO-2 X X X TRIO-3 X X X TRIO-4 X X X Etc….
2-5-Distribution formats EPMO has designed 6 distribution formats, and proposes them according to the needs of the customer. Each format has distinct characteristics:
Distribution Format
Type of tablets
Speed Allowable rotation of
Original cost
Cost of formats
Comments
Chute Easy flowing
Average - High
45° max Rotary brush
housing
Low Traditional solution
Universal brush box
Convex Average All Cassette Very low Traditional solution
Vibrating chute « all » Average - High
45° max Vibrating device & housing
Low
For tablets that would shingle in a chute
Rotary feeder « all » Very High 45° max High Dedicated cassette Tube feeder Easy
flowing High All High For high speed
intermittent motion blister machines
Feeding roll (Drum Feeder)
« all » Average All High ALU/ALU or specific feeding requirements
It is possible to attach several of these 6 distribution formats to one Combo Feeder. The choice of configuration (DUO-1, DUO-2… DUO-20 OR TRIO-1, TRIO-2... TRIO-20) will depend on the variety of tablets to be packaged. Combo DUO-1 & TRIO-1 are the most universal configuration. However, this configuration may not be appropriate for the specific needs of your products.
Page 14
COMBO FEEDER
2-5-1- Distribution by chute
The chute distribution consists of two grooved plates for tablet flow and a rotary brush made of rubber blades to mix the tablets.
The device is setup in two simple stages: • The two chutes connect to the base using a threaded axis • The upper unit is then attached by screwing the serrated roller into the base
Page 15
COMBO FEEDER
Rotary brush with blades for mixing tablets
The blades are made of food rubber
The chutes connect to the base using a threaded axis
Sensor for monitoring tablet level
Page 16
COMBO FEEDER
2-5-2- Distribution by box
The Box distribution is assembled by attaching the cassette and feed chute. The cassette is made of transparent plastic which allows monitoring of the tablet level in the mixing zone. It also considerably reduces the weight of the cassette. The box has integrated handles on the sides for easy handling. The brushes detach easily without tools. A removable lid permits access to the mixing zone in case of a problem. A chute directs the tablets to the beginning of the box where a sensor controls the arrival of the tablets. Once tablets are inside the box they are constantly mixed by specifically designed brushes. The last brush in the cassette consists of denser hairs and guarantees than only tablets properly positioned in a pocket can pass out of the box.
Page 17
COMBO FEEDER
Transparent cassette with Brushes
Handles
Removable lid
Feeding chute
Page 18
COMBO FEEDER
2-5-3- Distribution by vibrating chute
The vibrating ramp feeder has been developed for feeding difficult tablets such as:
• oval tablets • capsule tablets with small bevels • triangular tablets or other various shapes
It is capable of feeding almost all tablets that would otherwise shingle in a chute. Tablets flow down an inclined, grooved ramp mounted on a linear vibrator. A paddle brush helps guide the tablets into the grooves in the upper level. The vibrator prevents the jamming of tablets as they progress down the grooves. This type of feeder is primarily used for continuous motion machines, but can be installed on an intermittent machine if the Combo Feeder is mounted on a mobile carriage.
Page 19
COMBO FEEDER
Fast assembly of the vibrating device
installation by dovetail
easy to fasten
linear vibrator
Brush with rubber blades
Used to mix the products
Page 20
COMBO FEEDER
2-5-4- Rotary distribution
Rotary distribution is ideal for high speed feeding on continuous motion machines.
The rotating drum keeps positive pressure on the product from the hopper to the blister pocket. The feeder functions by driving tablets or capsules into grooved tracks on a rotary drum. The drum continually rotates which propels the tablet more efficiently than a static chute. This process increases the maximum feeding rate.
This feeder is appropriate for machines with high production rates and for large batches of product.
Rotary feeder consisting of: • a paddle brush which helps
move the tablets into the grooves of the drum
• a grooved drum to “push” the
tablets • a shoe for pulling the
products out of the roller and laying them down into the pockets
Page 21
COMBO FEEDER
2-5-5- Distribution by feeding roll (drum feeder)
The feeding roll is appropriate for products with specific feeding requirements. For example, this feeder is a good solution for ALU/ALU coldform blisters as it gently places the tablet into the blister without rubbing them on the web, which can damage the pocket. It can also be used to satisfy specific blister layouts such as pockets turned 90° to the direction of the web, different types of tablets in the same blister and even tablets turned on their side.
Feeding Roll consisting of: • A chute, vibrating ramp or flood
feeder guides tablets to a drum that has pockets matching the orientation of the blister card
• The motorized drum rotation is
synchronized with the web index of the machine through a sensor on the sealing station
• The product remains in a drum
pocket until it is released into the blister pocket
• The drum pockets retain the t
by either vacuum or a housing ohalf of the drum
ablets n
Page 22
COMBO FEEDER
2-5-6- Distribution by tubes
Tube feeders are appropriate for medium and high speed intermittent motion machines. They fill the entire index of the blister machine at once while the webbing is stationary.
Our tube feeder consists of cartridges with rows of connected tubes allowing easier assembly and cleaning. The current version of the EPMO tube feeder is interchangeable with Uhlmann SimTap cassettes. A version that is interchangeable with Aylward cassettes is under development and we are looking for a testing partner.
Tube feeder consisting of: • Tablets are fed into the product
distributor where they are dispersed above the tube openings
• The upper tray oscillates up and down
to assist tablets into the tubes • The middle tray ensures only a single
tablet is passed to the deposit tray at a time
• Each tube in the deposit tray is
aligned with a blister pocket and, when the machine stops, the tablet is released into the pocket
Page 23
COMBO FEEDER
2-6-Additional Devices EPMO has developed several additional devices which enhance the capabilities of the Combo Feeder. The Combo Plus is able to feed more then one product at a time into the same blister. The mobile carriage makes it possible for intermittent machines to run distribution formats otherwise only appropriate for continuous motion machines.
2-6-1- Combo device +
In the plus version, the Combo Feeder runs two simultaneous distribution formats allowing two different products to be fed into the same blister. The configuration depends on the number and the type of distribution solutions to be used. Example: Chute + rotary combination
Page 24
COMBO FEEDER
2-6-2- Mobile Carriage
A mobile carriage is available for the Combo Feeder that enables higher speed intermittent machines to utilize distribution formats otherwise only appropriate for continuous motion machines. When the blister web advances, the carriage moves the feeder forward while filling the pockets and then returns to its original position during the period that the webbing is idle.
• Brushless Motor
• Mobile Carriage
The mobile carriage serves the following purposes: • to use several feeder types
(otherwise mostly dedicated to continuous machines) on intermittent machines
• to have an autonomous mobile carriage integrated with the Combo Feeder
• to replace an existing mobile carriage that is not strong enough to support the Combo Feeder base
Principles of operation: • a brushless motor moves the
carriage up to 40 steps / min • carriage movement is synchronized
with that of the machine • it is possible to adjust the starting
position of the carriage according to each format
• the carriage consists of linear ball bearings and guide columns
Page 25
COMBO FEEDER
3- EXAMPLES OF CURRENT INSTALLATIONS
On a Servac PH3
On an Ima C60
Page 26
COMBO FEEDER
On Noack DPN 760
CONCLUSION The Combo Feeder has numerous advantages and it benefits various aspects of a blister line including: productivity, capacity, quality, image, flexibility, safety and control of the investment budgets.
The Combo Feeder was patented in France in 2005. This patent application was extended to European, American and Canadian levels.
We are at your disposal for any further information and please do not hesitate to contact our customer service.
ELIZABETH CARBIDE601 Linden Street
McKeesport, PA 15132USA
Tel : (412) 751-3000Fax : (412) 751-2390
E-mail : [email protected] : www.eliz.com
Top Related