ALF – fill and seal machines for ampoules and vials

2

ALF – the convincing line concept

The ALF series of machines meets all theprerequisites for modern ampoule produc-tion. The convincing line concept.Wide experience, state-of-the-art know-how, highly developed engineering andBosch quality – new dimensions for dependability, economy and flexibility with easy operator control.

The ALF series was configured in accor-dance with pathfinding, pharmaceuticallycompliant findings to provide a modern,ergonomic design that supplies the customer with maximum benefits.Decisive in this design is a basic machinethat can be equipped and retrofitted withvarious equipment units. These include: ❒ In-process control system❒ Closing station for vials❒ Infeed and outfeed starwheel ❒ Laminar Flow hood❒ Isolator version

Work and production considerations:

❒ Easy operator control due to the slim,tidy, clearly laid-out construction. Easycleaning.

❒ All machine functions can be overseen,controlled and operated from one position at the front.

❒ Clean Room compliance.❒ Drive and production segments are

clearly separated: worktop right through.❒ Virtually tool-free size changeovers.❒ Integrated testing technique, e.g. for

ampoule neck control (add-on device).❒ Laser sealing technique (add-on device).

ALF with the add-on equipment: pre-gasflushing, post-gasflushing, closuregasflushing and automatic, loss-free in-process control.

Output:

Up to 30.000/h.

3

One basic machine for various equipment units

Ampoule transfer wheel

ALF with the add-on equipment: pre-gasflushing, post-gasflushing,closure gasflushing and automatic,loss-free in-process control.

The ampoules are transferred directly fromthe sterilizing tunnel to the ALF infeed belt.Via a scroll conveyor and transfer wheelthe ampoules reach the conveying systemby means of which they are conductedthrough the work stations: gasflushing, filling, sealing. Each filling point controlsindividually contactless scanning of theampoule necks – "no ampoule – no filling".The ampoule necks are precentred by thedraw-off grippers, the ampoule tips are thengrasped and fed into a collection container.During the sealing procedure post-gasflush-ing can take place. The filled and sealedampoules are pushed virtually load-freeinto the outfeed magazine.

4

Precision filling systems for all product properties

Time-pressure filling system:

The Bosch time-pressure filling system issuccessfully used for a wide range of applications due to a multitude of advanta-ges:❒ Easy size changing with just a few low-

cost parts.❒ Pressure and temperature acquisition are

located right at the filling point.❒ Usable for all liquid products, especially

advantageous for shear-sensitive products.❒ All parts in contact with product are sui-

table for manual cleaning and sterilizingin an autoclave and for CIP/SIP.

Rotary slide pumps:

Bosch provides precision filling for parente-ralia with its proven rotary slide pump. Product-conserving and drip-free filling tothe highest degree of filling precision areensured for a wide range of different properties.Bosch seal-free rotary slide pumps haveeasy vertical cleaning paths.

Technical in the lead:❒ 3-part: rotary slide valve, pump cylinder,

pump piston.❒ Seal free.❒ Easy, vertical cleaning paths.❒ CIP/SIP capability.

Rotary slide pumps.

Rotary slide pumps made of stainless steeland ceramic material.

Time-pressure filling system.

Time-pressure fill system and in-pro-cess control.

5

Add-on devices, laser sealing technique

Sealing ampoules by the laser technique.

The energy required for preheating anddrawing off the ampoule neck is generatedby a CO2 laser. The system provides a special advantage for ampoule fill and sealmachines that are equipped with an Isola-tor. The laser unit is set up outside of theClean Room A. In comparison to conven-tional sealing with gas and oxygen thissystem is practically particle-free, flow-freeand produces considerably less heat.

Protective gasflush-ing prior to filling

Filling station(standard)

Inert gasflushing after filling

Gasflushingduring closing

Laser sealing station

Due to this no elaborated extraction of heatin the preheating and draw-off station isrequired. Flame adjustment, which isdependent on the glass and is often verysensitive, is dispensed with. Due to storageof the adjustment data the settings arereproducible and at the same time a considerably faster and simpler size change-over results.

6

Add-on devices: in-process control, double outfeed

Discharge of containers into a tray forin-process control.

Discharge of containers into a tray forin-process control.Automatically switchable double out-feed.

Fully automatic, loss-free in-processcontrol of the filling weight.

Fully automatic in-process control, weighing position.

Fully automatic in-process control,Touchscreen PC.

7

Add-on devices: sealing station for vials

On the version of the processing of bothampoules and vials the 4-point and 6-pointbasic ALF machines can be equipped (andretrofitted) for different size and output ranges.

ALF multi-purpose machine, linear outfeedvia scroll conveyor.

ALF multi-purpose machine for ampoulesand vials: right-angled outfeed via scrollconveyor.

CIP/SIP time-pressure filling station, SIP gasflushing stations.

Product containers with min./max. controlunit mounted on the distribution pipe.

8

ALF multi-purpose machine, right-angledoutfeed scroll conveyor

Feed star (with right-angled arrangementof the sterilizing tunnel and on the multi-purpose machine). Right-angled discharge conveyor

Gas installation package

Right-angled feed and discharge conveyors, wall installation,gasflushing

Wall installation

9

Size parts

Sizepart set for infeed,with tunnel installed at right angle.

Size set for standard machine.

Size set for right-angled outfeed Size set for IPK.

10

Bosch is number 1 worldwide in Isolator engineering

The leading pharmaceutical companieshave set themselves the objective of marketing innovative products, which iswhy they back Bosch’s innovative Isolatorengineering.In the pharmaceuticel industry Isolatortechnology is gaining ever greater im-portance due to its clear production advantages. Comparisons with convention-al sterile room technology have been dealtwith in a multitude of technical articles andsymposia. There is a clear trend towardsthe Isolator technique.The advantages of personnel and productprotection are what makes isolators thetechnology of the future. Bosch has provenits leading position because it has the largest share of the total number of Isolatorinstallations supplied.

Example of a compact ampoule installation with separately standing ven-tilation unit.

Slim construction.

11

Ampoule compact line

2750

26

50

2750

90

0

10

85

Robert Bosch GmbHPackaging Technologie DivisionPharma Business UnitBlaufelder Straße 45D-74564 Crailsheim

Postfach 14 54D-74554 Crailsheim

Telephone +49 79 51 40 2-1Fax +49 79 51 40 2-2 58E-mail: vt@boschpackaging.comInternet: http://www.bosch.de/pa

Robert Bosch Ltda.Tecnologia de EmbalagemRua Dr. Rubens Gomes Bueno, 47804730-901 São Paulo-SP/BrasilTelephone ++55 11 5547 5709

++55 11 5547 5831Fax ++55 11 5547 5906http://www.bosch.de/paE-mail: vtbr@boschpackaging.com

Bosch Packaging Technology K.K.Hatchobori NF Bldg., 4F2-21-6, HatchoboriChuo-kuTokyo 104 0032JapanTelephone +81 3 3206 2821Fax +81 3 3206 2822E-mail: vtjp@boschpackaging.com

Bosch Packaging Technology NAPharmaceutical8700 Wyoming Ave. NMinneapolis, MN 55445-1836USATelephone +1 763 424 4700Fax +1 763 493 6711E-mail: pharm-na@boschpackaging.comInternet: http://www.boschpackaging.com

Technical specifications

All dimensions in mm

Subject to technical modifications.

Graphic illustrations in this leaflet are examples only! Determinant for the final execution, including technical specifications,is our individual quotation exclusively.

Containers, machine type, container size, output:

Type Vol. (ml) Ø (mm) H (mm) Adjusted throughput

Ampoules ALF 4040 1 - 30 9 - 30 60 - 160 1 - 2 ml: 200/min

ALF 4060 1 - 30 9 - 26 60 - 160 1 - 2 ml: 300/min

ALF 4080 1 - 30 9 - 22,5 60 - 160 1 - 2 ml: 400/min

Ampoules ALF 4040 2R - 30 R 14 - 30 35 - 75 2R: 200/min

and combi 5H - 30H 5H: 180/min

vials ALF 4060 2R - 30 R 14 - 26 35 - 75 2R: 300/min

combi 5H - 30 H 5H: 270/min

PA/A

DV

· 03

/04

· 1 E

· A

rnol

d 73

779

Dei

zisa

u · P

aper

: whi

te, w

ithou

t chl

orin

e ©

All

righ

ts r

eser

ved.

IWF