chef jay's food | fully automated packaging of protein bars
TRANSCRIPT
Chef Jay’s Food | Fully automated packaging of Protein BarsNovartis | Flexible blister line installed successfully Warner-Chilcott | Innovative packaging for birth control pills
packazineIssue 01/2006
2 | packazine Table of contents | Editorial
Cover
Packaging declarations for Food,
Non-Food and Pharmaceuticals.
News
Corporate News
04 A 3 pack of centuries
06 Expansion in China
Facts & Trends
08 Unwrapping the information on packaging
Customers & Markets
Food & Confectionery
10 Induban | Coffee Dreams from the Dominican Republic
12 Team Spirit strength through unity
14 Nong Shim | Delicate Noodles from the Far East
18 Pull Pack – another step towards convenience
20 Chef Jay‘s Food Products | Fully Automated Packaging Solution Extends
Production Flexibility for Nutriceutical Protein Bar Manufacturer
Pharma & Cosmetic
23 Warner-Chilcott | Innovative Pack-Style for Birth Control Pills
26 Merckle Biotec | Precision all the way along the line
28 Astellas | Capsule filling and sealing lines from a single source on the march
30 “Shut the door” for improved quality – Barrier systems from Bosch
32 BRISTOL MYERS SQUIBB | High-performance packaging systems
for pharmaceutical powders and granulates
34 Novartis | Flexibility counts. Blister line successfully installed at Novartis, UK
Other Markets
37 Service | New customer-specific training courses
39 Sigpack Systems | 100 years of innovation in the service of packaging
41 Events | Inprint
42 SWEEPSTAKES | Tell us what you think of our packazine
Win an iPod or an IXO cordless screwdriver
20 23
Table of contents
packazine | 3
34
Dear Readers,
I am particularly delighted that this year we can
celebrate several anniversaries at the same time! In
1906 Sapal supplied the first packaging machine for
chocolate bars. At that time SIG (now Sigpack Systems)
produced this first packaging machine on behalf of
Sapal. This was the foundation for a successful col-
laboration that still continues today. 100 years later
under the umbrella brand of Bosch both companies
are part of the world’s best-known group of packaging
machinery and systems manufacturers. Together with
our company here in Germany, Robert Bosch in North
America is also celebrating its 100th anniversary.
The name of Bosch Packaging Technology stands
for quality, reliability and regional presence. Thanks to our experience and your
confidence, we can look back on a successful history of machine building. In
the future we will continue to build on these long-term partnerships with you.
In this edition of the Packazine we have once again sought out for you
interesting reports on applications in the pharmaceutical, confectionery,
food and non-food industries. Because of the forthcoming ACHEMA
we are focusing on pharmaceutical solutions. We’d be happy to intro-
duce you to some of these solutions in person at the trade fair!
“Pharma Solutions like you have never seen before”. This is the slogan under which we
will be exhibiting at this year’s ACHEMA in Frankfurt. We are underlining the close co-
operation between our companies and the strategic orientation that they share with
a refreshing worldwide advertising campaign using this slogan. To mark this trade fair
we are showing you our broad product portfolio for the pharmaceutical industry. The
focus will be on innovative applications for syringes and customer-specific solutions.
Do you like our magazine? We want to gear the Packazine to suit your needs
as far as possible. Please return the questionnaire of page 42 to us with
your suggestions and we will automatically enter you in our sweepstakes.
I’ll keep my fingers crossed for you!
Friedbert Klefenz
Friedbert Klefenz
President Bosch Packaging
Technology
Editorial
4 | packazine News Corporate News
A 3 pack of centuriesThis year Bosch has 3 centenaries to celebrate. Three different
centenaries coincide in the Bosch family, now celebrating 100 years
of existence.
Sapal – Société Anonyme des Plieuses
Automatiques, Lausanne – opened its
doors on 2 August 1906. Four weeks lat-
er, on 2 September 1906 Robert Bosch
USA set out on the road to success with
a start-up capital of $ 25,000. In the
same year, SIG (Schweizerische Industrie
Gesellschaft – the Swiss Industrial Com-
pany), now Sigpack Systems, manufac-
tured its first packaging machine (in the
then weaponry department) under sub-
contract from Sapal.
After an advertising campaign for
magnetos
resulted in an overwhelming demand,
Sales Engineer Gustav Klein founded the
first overseas agency in New York. The
US market grew so quickly it soon be-
came necessary to build factories there.
Today, Bosch USA has a staff of almost
18,000 at about 80 locations. These
figures include just under 600 people
at 4 locations working in the Packaging
Technology area.
The 100th birthday is a good reason to
celebrate the entire year and to look
back at the successes of the past. The
high point of the celebrations is the ex-
tensive gala to which customers from all
sectors will be invited. The company’s
history will also be featured in a special
publication, on the company’s website,
and in a film.
The first packaging machine for
chocolate bars
was based on a patent filed in the USA
in 1900 by a German engineer, Rich-
ard A. Berger, for a mechanical device,
which made the packaging of products
in the shape of bars or cubes possible
in a single step (die folding). Founded
by a group of investors, Sapal had only
a Sales Department at that time. A De-
velopment Department for the company
and a production facility followed shortly
afterwards. The actual assembly of
machines began in the year 1919. Having
sold altogether more 10,000 machines
worldwide, Sapal now has a staff of
about 100 employees. For the centenary,
Sapal created a slogan that summarizes
its history of creativity, reliability and
quality in packaging - “Fashion for Food”.
The centenary will be celebrated with a
Family Day in June and an Open Doors
Day on 30 September 2006.
Sigpack Systems has undergone the
transformation
from machine manufacturer to system
provider during its 100-year history.
Please see the detailed account of the
transformation on page 39.
For more information please contact:
Bernard C. Fenner
Phone +41 52 674 7419
+ = 100 % Bosch+
packazine | 5
www.bosch.com/pa
Pharma solutions like you have never seen before.
6 | packazine News Corporate News
Expansion in China
In China, the demand for packaging machinery
has been increasing at an incredible rate of 25 %
per year between 2000 and 2004.
Long success story
Bosch Packaging Technology is a world
market leader in innovative packaging
technology. Bosch Packaging Technol-
ogy (Hangzhou) Co., Ltd. was founded
at the beginning of 2001 as an entirely
foreign-owned company and is locat-
ed in Hangzhou, about 180 km west of
Shanghai. Starting with 14 employees
in 2001, the company grew quickly and
currently (2006) has more than 130
employees.
Business fields
We produce and provide various types
of pharmaceutical packaging machin-
ery, such as capsule filling machines
and syringe fillers, for the industries in
China and South East Asia. In addition,
Bosch Packaging Technology Hangzhou in the near future
packazine | 7
we have expanded into other business
fields, namely for food and confection-
ery packaging. In 2003, we began the
manufacture of the TERRA 25 bag form
fill and seal machine, followed one year
later by the SVE 2510, a sophisticated
high-speed bagger. Chinese customers
producing candy and other confection-
ery also enjoy the market presence and
technology provided by of our plant in
Hangzhou.
Plant expansion
Because it is our goal to better serve our
customer while supporting them with a
continuously increasing range of machin-
ery, we realized that our current produc-
tion site had simply become too small.
Therefore, in early 2005, the Bosch Pack-
aging Management decided to expand
with a new facility. On 10 November
2005, all company associates witnessed
the exiting and important moment – the
groundbreaking ceremony. Despite cold
and rainy winter weather, construction
work proceeded as scheduled in order
to be ready in time for the roof closing
ceremony in early April. The new plant
will be put into use in August 2006. Then,
on a total area of 35,000 square meters
and with a workshop of 15,000 square
meters the new plant will become the
biggest R&D center and production
base for Bosch Packaging Technology
in Asia. We believe that with this expan-
sion, Bosch Packaging Technology in
Hangzhou will enjoy additional success-
ful growth, continue to participate in the
dynamic development of the Chinese
and Asian markets, and be the right
partner for all our Asian customers!
For more information please contact:
Maggie Zhou
Phone +86 571 8893 5526
Left:
23th February 2006 our
building is like this
Right:
Groundbreaking ceremony in
Hangzhou
8 | packazine News Facts & Trends
Statements on packaging and their
meanings
Part of the marking on packaging is sub-
ject to country-specific legislation. This
includes product data which controls the
movement of goods, gives information to
the consumer and protects the product
against theft or tampering. But of course
the packaging must primarily provide
information on the properties and con-
tents of the product.
Thus the following information can al-
ways be found on food and pharmaceuti-
cal packaging:
● The name of the manufacturer and the
country of origin
● The name of the foodstuff or pharma-
ceutical product
● The “best before” date and expiry
date
● Ingredients and additives / composi-
tion of the drug
● Quantity and price
Hidden packaging information
unwrapped
But if you look more closely at the pack-
aging, you will see information, which
at first sight seems to be unimportant,
incomprehensible or even invisible to
the consumer. In this era of brands and
their imitators, more and more software-
based marking techniques are being em-
ployed to prove that products are genu-
ine and to protect the manufacturer and
customer alike. What does this and other
“packaged” information actually look like?
European Article Numbering(EAN)-code/
barcode
The most common form is the printed,
machine-readable barcode, which plays a
significant role in making the movement
of the goods from the manufacturer to
the consumer easier and faster.
Pictograms / Symbols
Pictograms and symbols have proved
to be very useful in providing important
consumer information without running
into the problem of language barriers,
e.g. as warnings or washing instructions.
Braille
In Germany, all pharmaceutical packag-
ing will have to incorporate information
in Braille from September 1, 2006 follow-
ing a change in the law. Braille will also
be used increasingly on household arti-
cles and foodstuffs.
Thermo-sensitive colors
Temperature-sensitive colors on pack-
aging (e.g. on milk packaging) indicate
whether a product has been overheated
and is therefore safe for consumption or
not.
UV colors
This type of “hidden” information is only
visible under UV light. This technology
has already proved its worth in indicating
whether banknotes are genuine or not.
Tamper-evidence bands
These bands are used, for example, on
screw tops and a damaged band indi-
All pharmaceuticals and a large proportion of the foodstuffs we
consume today are packaged. Although the main purpose of the pack-
aging is to protect the contents, it also serves to provide a range of
information about the product, e.g. on its composition or correct use.
But the packaging also often contains hidden, encrypted or invisible
messages. What information is important to whom?
And, what does it all mean?
Unwrapping the information on packaging
packazine | 9
cates that the bottle or jar has been
opened at least once.
Grids and micro texts
These logos or texts are only visible with
the aid of a special film or magnifying
glass.
Labels
Holograms (3D images) and RFID labels
are being increasingly used for pharma-
ceuticals.
In the case of RFID (Radio Frequency
Identification), product data is stored
on a rewritable microchip, which makes
checks in different locations (along the
distribution chain, supermarket check-
outs) very easy.
Bosch Packaging Technology is of course
also embracing this promising modern
technology and is a skilled partner for
you.
Intelligent packaging in a dialog with
the future
Whatever solution is adopted as a firm
component of a packaging item, it must
contribute to the provision of relevant
product information to all persons along
the process chain. At the same time, eco-
nomic handling, international standard-
ization and the trouble-free and safe dis-
posal of packaging play an increasingly
important role. The packaging of the fu-
ture will therefore become more secure,
more intelligent and more informative,
without becoming more cumbersome.
For more information please contact
Denise Beele
Phone +41 52 674 80 53
Coffee Dreamsfrom the Dominican Republic
Industrias Banilejas – a traditional
family business
With a high market share, the traditional
coffee company Industrias Banilejas en-
joys an excellent reputation with its cus-
tomers in the Dominican Republic. Led
by “Don Rafael”, the company’s secret
to success is based on the integration
of the processes. The coffee beans are
cultivated on company-owned planta-
tions where 1’200 employees tend to the
coffee production and packaging, deal-
ing with every phase through delivery.
Induban coffee can be bought in almost
every store in the Dominican Republic.
Modern techniques for a time-tested
partnership
Up to now, coffee from Induban was
packaged on three reliable Bosch PKS
package makers. After twelve years of
high customer satisfaction with the tech-
nical aspects and particularly the excel-
lent support supplied by Bosch, Indu-
ban once again decided in favor of this
trusted partner. Last May 2005 an order
was placed to continue reaping the ben-
efits of increased flexibility in day-to-day
production: Using the new PMC 4202 BG
Induban is able to package ground coffee
as well as whole beans while also being
convinced of it’s unbeatable cost-effi-
ciency ratio.
The coffee producer Induban will continue to count on Bosch Packaging
Technology. The PMC 4202 BG offers even more production flexibility –
at an unbeatable cost-efficiency ratio.
10 | packazine Customers & Markets Food & Confectionery
Product-conserving packaging
at a high output rate
Two FVS 3101 SQ auger fillers and one
FIW 4011K net weigher are used to pack-
age ground coffee or whole beans. The
low drop height allows a particularly
gentle handling of the product. Due to
the compact design of the auger filler
FVS and the net weigher FIW a setup
with a combination of both on top of one
bag-making unit is possible. This offers
Industrias Banilejas the benefit of the
best dosing technique for whole bean as
well as ground coffee. Two parallel bag-
making units help yield the high output
of the line with up to 95 packages per
minute. The flexible PMC 4202 BG manu-
factures three different sizes of the
coffee package with adhesive tape and
corner creasing of Induban’s choice.
Success based on experience
Industrias Banilejas has been a satis-
fied Bosch customer for many years and
cherishes the close personal relation-
ship with their competent contacts at
Bosch as well as the first-rate Bosch sup-
port. An example in this context would
be the successful conversion of the ex-
isting lines to incorporate a new IPC
control system. However, making a deci-
sion in favor Bosch was aided by another
customer’s experience: During a visit to
a large German coffee roaster, Induban
was able to see a PMC 4202 BG machine
in operation and receive a first-hand im-
pression of the production advantages.
Convinced by the proven quality, ad-
vanced technology, first-class project
management and service the transaction
was finalized by a handshake at Inter-
pack in April 2005. Since February 2006
Industrias Banilejas is running the PMC
4202 BG successfully in operation.
For more information please contact:
Martin Kühl
Phone +49(711)811-57480
from left to right:
Rafael Portillo, Plant
Manager and Head of
Industrias Banilejas
Rafael Perelló
Coffee packaging line consisting of:
1 package maker PMC 4202 BG
2 auger fillers FVS 3101 SQ
1 net weigher FIW 4011 K
1 valve applicator CVA 2000 VIS
1 check weigher KWI 3010 N
packazine | 11packazine | 11
12 | packazine Customers & Markets Food & Confectionery
Team Spirit Strength Through Unity
Right at the official start of the Packaging Machines Business Unit
(PA-PM), Demaurex SA, Tevopharm BV and Transver AG combined their
forces to meet the demands of their customers.
A Chinese proverb says: “The superior
man acts before he speaks, and after-
wards speaks according to his action“
– a quotation perfect for the Packaging
Machines Business Unit: right after an-
nouncing the creation of the new busi-
ness unit and acting as a team, a joint
project by Demaurex, Tevopharm and
Transver was already underway.
Exquisite Biscuits
In the year 1870 the pharmacist Charles
Delacre started his own company with
the same name „Delacre“. He prescribed
chocolate as a remedy for his pharmacy
customers and was so successful with it
that he opened his first factory in 1891.
He already produced at that time inge-
nious new biscuits at a Patisserie level.
Delacre then requested a flexible adapt-
able packaging solution for his individual
fine creative biscuits.
A win-win situation
One or several Delacre cookies are
wrapped at a time and then put into
boxes with the Flowpack machine. Tevo-
pharm performes the wrapping process
and Demaurex provides the pick-and-
place operation. Transver, a conveying
specialist, was the missing link to bring
the project to life. Compatible yet stand-
alone, the Demaurex and Tevopharm
machines can interlink directly and feed
a Pack-200 with Delfi, or use a Transver
conveyor for a different configuration.
In this case, the cookies travel on
Transver belts conveyors, pass through
Demaurex Delfi and the Tevopharm
wrapper, return on Transver belts and
finally feed into a Demaurex Presto
Dual Collator. Not only products pass
from one machine to the next, data is
also exchanged. The Delfi systems pro-
vide the Pack-200 with its input rate so
the wrapper to adjust its own speed,
increasing the line’s efficiency.
1 Transver TD Conveyor, hygienic,
convenient and safe.
2 Tevopharm pack-200, the medium speed
servo driven flowrapper
3 Presto Top Loader for automatic box
packing wrapped products.
Demaurex Delfi for feeding wrapper
packazine | 13
Tevopharm Pack-200
The modular Pack-200 is a medium speed
versatile flow wrapper. It is equipped
with a minimum of mechanical parts and
has many of the same identical parts of
the successful Pack-2000.
The Transver conveyors
Transver is indisputably a conveying sys-
tems expert. The compact design of their
conveyors allows easy integration. With
smooth surfaces and avoidance of nooks
and edges, their belts have a long ser-
vice life under tough working conditions.
Transver is the perfect interface for pack-
aging machine modules.
The Demaurex Delfi
More than just locating the products
to pick, the current Delfi offers a large
range of quality controls. With a new
vision system based on the latest known
algorithms, it is now easy to sort and
choose the products to be packaged.
The Demaurex Presto Dual Collator
The Demaurex flexibility continues. With
two independent collating chains, this
evolution of the famous Demaurex Top
Loader offers even more capabilities of
integration: merging two separate flows,
synchronized or not, is now a standard
feature, even with two different products.
PA-PM believe in progress
In close collaboration and by sharing
their know-how, the Packaging Machines
companies supply solutions combining
years of experience and mastery in all
packaging application fields. The future
development will be driven in this direc-
tion to improve the product quality and
the services of the Business Unit. As
another Chinese Proverb stated:“ The
whole is more than the sum of its parts.“
For more information, please contact:
Dr. Marc-Olivier Demaurex
Phone +41 21 644 25 35
1 2 3
14 | packazine Customers & Markets Food & Confectionery
1
Output 100 % higher
than the past system
with outstanding 98.5 %
efficiency.
2
DAC-Compact Buffer
Easy and convenient to prepare with added
products in sachets.
1 2
packazine | 15
Delicate Noodles from the Far East
In Asia, noodles are an established
mainstay of the daily meal. The
convenient pack with noodles and
spices is enjoying increasing popularity
in the West too.
They are ready to make – prepare
– heat and eat!
The rising pressure to reduce prices
means that these products must be
packed at high speed with extreme care
and at low cost. Sigpack Systems has
commissioned over a dozen packaging
lines for noodles in Asia.
As one of the most popular common
foodstuffs in Asia, noodles are to be seen
everywhere. For many people, a «noodle
nest» often constitutes an entire meal.
Because they can be prepared in a flash,
they are constantly finding new fans –
not only in Asia but in Europe and in the
USA, too.
Growing consumption prompted Nong
Shim, the leading manufacturer of noo-
dles in Korea, to increase its production
capacity and to modernize its packaging
hall accordingly. In order to consolidate
its leading position, it was necessary to
improve the efficiency of the entire pro-
cess. Under no circumstances was the
price to increase. Sigpack Systems was
able to offer the high-speed solution de-
sired by Nong Shim.
Noodles on-the-go
52 rows of 10 noodle nests with a dia-
meter of 130 mm, leave the manufactur-
ing process every minute. The individual
rows are aligned accordingly and any ir-
regular nests are automatically rejected.
The noodles, with a temperature of
110°C from the process are fed into the
new DAC compact buffer with a capac-
ity of up to 7 minutes. The integrated
cooling in the buffer section reduces the
temperature down to 35°C. Two lines are
fed at the same time with a maximum
out fed of 64 rows per minute. A weight
station checks the product before it is
provided to the FBF inline infeed with
string belts. The crumbs fall so directly
into the catch-trays to prevent problems.
16 | packazine Customers & Markets Food & Confectionery
Synchronization at its best
An outstanding detail is the simultaneous
packing of up to three sachets containing
the powdered flavouring, dried vegeta-
bles and oil. Two FVV sachet loaders fed
each up to 350 sachets per minute. The
sachets that are fed in on one track are
cut, placed on top of the noodles and
on top of each other. The feeding speed
of the sachet loader corresponds exactly
to that of the chain that transports the
noodles. This prevents the sachets from
slipping. The pusher is constructed in
such a way that enables it to transport
the sachets and the noodle nests gently
to the packaging station.
The request for variable sachets in a flow
pack is increasing and gives new oppor-
tunities also for established products.
Speed is at a premium
Output is 100 % higher than that of the
past system. We are talking, of course,
about the output that can be achieved
with the new high-speed packaging line.
Two HBM pillow pack machines pro-
duce a total of up to 640 hot sealed OPP
packs a minute. Nong Shim produces its
own film material. The sealing equipment
has been adapted to the characteristic
of this excellent OPP film, to allow high
speeds at shorter sealing times.
The efficiency of this high-speed packag-
ing line for noodles in the Far East lies
with outstanding 98.5 % even higher than
guaranteed by Sigpack Systems. The en-
tire system is fitted with a very slim line
layout. Any problems that may arise are
displayed on a screen. Only three people
are required to run both packaging legs.
Their tasks are limited to monitoring, reel
changes and minor maintenance work.
The customer is extremely satisfied with
the new system, not least thanks to the
high level of support provided by Sigpack
Systems throughout the planning,
construction and commissioning stages.
For more information please contact:
Urs Schweizer
Phone + 41 52 674 65 14
1 Product from Process
2 Aligning and Quality Check
3 DAC Compact Buffer
4 Cooling Section Buffer
5 Double Buffer Distribution
6 Weight station
7 FVV Sachet Feeder
8 HBM Flow Wrapper
12
3
4
5
67
7
8
packazine | 17
If you’re looking for product handling that is out of the ordinary, that is as special and unique as your product, we are the partner for you. We have proven expertise, which provides fl exibility and innovation to your existing equipment or to a new line. Our standard platforms easily fi t individual customer requirements, provide lower costs and reduce delivery time. Bosch Packaging Services guarantees regional presence and solid know-how for all products. Day or night, around the clock.
Product handling like you have never seen before.
www.bosch.com/pa
sujet_21.indd 1 30.3.2006 18:05:43 Uhr
18 | packazine Customers & Markets Food & Confectionery
Pull Pack – another step towards convenienceSigpack Systems is developing “Pull Pack” – an
innovative opening mechanism for a widely used and
well established style of packaging. A prototype is
already under construction.
packazine | 19
Imagine that right now you’re reading a
good book or riding your bicycle. You’re
dying of hunger. You’d love to have a bite
of your favorite bar. But how can you un-
wrap the bar easily and quickly – with
one hand and without touching the prod-
uct? An illusion? No, because with Pull
Pack “convenience dreams” come true!
Simple to open
In contrast to the opening aids in regu-
lar use today such as tear tape, perfora-
tions, zig-zag cuts, etc., Pull Pack can be
opened easily and in a controlled man-
ner. You hold the product in one hand
and use your other hand or your teeth
to pull on the seal fin along the shorter
edge of the packaging. The product with
its packaging sits firmly in your hand and
immediately the bar is ready to eat. And
you can do it under any circumstances.
New marketing possibilities
The controlled opening of the pack and
the clearly defined pulled off section of
the packaging opens up all sorts of pos-
sibilities for marketing. For example, the
pull-off section of the packaging could
be used as an object to collect for a
competition. It could also be used in a
co-sponsoring project for advertising the
2006 World Soccer Championships or
the Super Bowl – or, for children, the
latest Disney cartoon. These are new
opportunities that could help to position
the product afresh and thus boost sales.
Letting pictures speak
for themselves
With packaging, communi-
cation is an important key
to success, whether it be for
a new product, a new
type of taste or even for a new
feature on an existing product. There are
a variety of options for clear communica-
tions. With pictograms, for example, it
is possible to illustrate how something
works very easily and in a way that every-
one can understand.
New, old-style packaging
The delightful thing about it is that Pull
Pack does not represent a complete-
ly new style of packaging. Rather, this
opening mechanism is an innovative
further development of a widely used
and well established style of packag-
ing – another very important argument
when it comes to investment. Pull Pack
requires no new machinery and also no
new process. It only requires one addi-
tional module for existing flow wrapping
machines. That’s all you need in order to
apply the opening aid.
Consumers are impressed
A survey of consumers which was car-
ried out recently elicited many positive
responses. Most reactions show that the
opening mechanism brings practical
benefits. It’s simple, neat, clean, quick,
fun and has novelty attraction.
The physical “tug” when
you open a package
surprises you and is
fun at the same time.
Consumers say:
● “It’s easier when you’re
traveling”
● “It’s easier when you’re driving”
● “You don’t touch the bar with your
fingers”
● “It protects against dirty fingers”
● “It’s really easy to open”
● “It’s just one movement – it’s clean”
● “There’s no torn foil that has to be
held down”
Implementation of the technology
already underway
The idea for an innovative method
of opening of a package alone is not
enough. Of course you also need the
appropriate mechanisms so that it can
be implemented efficiently in the pack-
aging process. The additional module
which can be applied to existing flow
wrapping machines is currently being
developed by Sigpack Systems. The first
prototype is already under construction.
The aim in future is also to be able to run
trials for our customers using this
prototype alongside the actual develop-
ment work.
For more information please contact:
Bruno Oberle
Phone +41 52 674 6357
to success, whether it be for
type of taste or even for a new
feature on an existing product. There are
The physical “tug” when
you open a package
surprises you and is
fun at the same time.
Consumers say:
● “It’s easier when you’re
traveling”
● “It’s easier when you’re driving”
Quick, clean and simple
– that’s how the bikerider
enjoys his bar
20 | packazine Customers & Markets Food & Confectionery
Fully automated packaging solution extends production flexibility for Nutriceutical Protein Bar Manufacturer
packazine | 21
Demand for healthy protein bar leads
to efficient packaging line
Growing production demands led the
company to implement more efficient
packaging machinery to replace its cur-
rent manual processes. Littmann chose
to partner with Doboy Inc.: “The com-
pany’s quality of equipment and com-
mitment to service were the reasons for
my investment. Doboy could address
all of my packaging concerns. They had
everything I need including horizontal
wrappers, carton formers, carton clos-
ers, robotic placement of the soft pliable
bar into wrappers and the loading of the
wrapped bar into the carton.“
Efficiency in the making
The extruded bars are then conveyed
to Doboy’s Robotic Delfi Feed Placer
equipped with three robot arms and ad-
vance vision tracking for continuous pro-
duction flow to pick and place the bars
efficiently. Currently, 200 bars per min-
ute can be placed, although the Delfi of-
fers speeds of up to 400 bars per minute.
This allows for Littman‘s planned growth
potential. The bars in the Delfi Feed
Placer come in a dense, random order
and orientation, thus eliminating the
need to space rows of products as with
traditional product distribution, which
requires much more floor space.
Utilizing the advanced tracking system,
Delfi’s vacuum cup end-effectors con-
sistently pick and place the protein bars
directly into the wrapper‘s moving lug
chain.
Simplified equipment changeover
furthers flexibility
The bars are fed to a Doboy Linium 301
horizontal flow wrapper from the Delfi
Jay Littmann, owner of Chef Jay’s Food Products, recently moved from
his muffin shop to a modern 50,000 square foot facility to manufacture
Tri-O-PlexTM super protein bars, a variation of his original health bar.
High in protein and fiber, the bars are made with whole grains for health-
conscious consumers and international suppliers.
Presto Top Loader and 7520 former Bars in the lugchain on their way to the wrapper
from left:
Jay Littmann, owner of Chef
Jay‘s Food Products and Jeffrey
L. Jackson, Product Manager
Pharmaceutical Operations
22 | packazine Customers & Markets Food & Confectionery | Pharma & Cosmetic
robot. “The flexibility of the Linium 301
wrapper and Delfi Feed Placer provides
the type of automation we need,” stated
Littman. Doboy’s Linium 301 wrapper is
a rotary-head horizontal wrapper with
the options of manual, semi-automatic or
fully automatic feeding. The Linium 301’s
servo-driven infeed conveyor interfaces
with the Delfi Feed Placer for variable
speed based on product flow and proper
placement with incredible accuracy. The
wrapped bars convey to a Doboy Model
7520 Carton Former forming two cartons
at a time. The formed carton backlog is
photo-eye monitored to ensure a pre-
cise carton flow necessary based on up-
stream demands. The current production
line has the cartons traveling in one di-
rection. As the product line grows, there
is an option to form two cartons. These
would then travel in opposite directions
to service two separate lines.
Finishing steps
The formed cartons travel to a Doboy
Presto Top Loader where they are filled
with rows and layers of wrapped bars.
Advanced tracking software picks the
product off a moving collation chain and
top loads the moving carton. The exact
location of the bars and cartons during
the pick-and-place process is tracked by
software, therefore only one collation
chain is necessary, which in turn
requires but a small footprint robot only
4 foot wide x 4 foot long. The filled car-
tons then enter the Doboy 840e Tri-Seal
Carton Closer, at up to 30 cartons per
minute. The Doboy 840e accepts random
carton flow and accurately stages the
cartons prior to gluing. The integrated
Nordson Bravura Hot Melt Unit ensures
an accurate glue pattern. Once closed,
the cartons are ready for shipment.
Bright future for increased production
and international distribution
Chef Jay’s is now a leading supplier of
high-quality Tri-O-Plex™ bars in 13 fla-
vors shipped to major nutrition suppli-
ers across the nation and to parts of
Canada, Australia and Europe. Doboy’s
complete packaging solution allows the
company to now package up to 240 bars
per minute, more than twice of what
was achieved through manual labor. “We
like the flexibility of the new Doboy line
and its ability to accommodate differ-
ent product shapes and sizes,” Littmann
concluded. “This flexibility will allow us
to add new product lines in the future
and we anticipate Doboy will be there
with us every step of the way.”
For more information please contact:
Jane Burbach
Phone +1 715 243 2559
Delfi Feed Placer places bars into the
wrapper
Carton in 840e closer
Delfi Feed Placer and Presto Top Loader
packazine | 23
Innovative Pack Style for Birth Control PillsSigpack Systems is helping Warner-Chilcott to increase
productivity, ensuring uninterrupted supply of hermetically
wrapped blisters of birth control pills.
High technology in a Caribbean
environment
Not only does Puerto Rico have a fantas-
tic year-round climate in an ideal setting,
it also has more pharmaceutical manu-
facturing facilities than one can imagine.
Warner-Chilcott is located an hour’s
drive out of San Juan on the eastern side
of the island of Puerto Rico.
Warner-Chilcott’s existing packaging op-
eration produces blisters filled with birth
control pills. Currently the majority of
blisters are wrapped together with a
patient insert, a wallet holder and a des-
iccant. Some are even sealed hermeti-
cally.
Overcoming challenges
Increasingly though, Warner-Chilcott
wraps all blisters hermetically and with
their existing wrappers could no longer
fulfill the climbing production demands.
Enter Sigpack Systems: to meet the chal-
lenge, Sigpack supplies its HBL machine
– highest-speed hermetic wrapping sys-
tem on the market – to Warner-Chilcott.
Complete system solution
There are four components (blister, wal-
let holder, patient insert, desiccant) to
be consistently fed into the wrapper at
a rate of 175 units per minute. It is criti-
cal to design the component feeders to
match up seamlessly with the wrapper’s
capabilities. All components entering the
24 | packazine Customers & Markets Pharma & Cosmetic
wrapper chain are verified. The system
includes a sophisticated feeding control
which verifies the existence of each com-
ponent with integrated latch out func-
tion to reduce waste of material. Only a
product properly wrapped with all com-
ponents is able to travel on to the down-
stream cartoner. Since the product car-
rier chain and cross-crimper head run on
independent servodrives, Sigpack Sys-
tems incorporated the “no-gap / no-seal”
feature. This provides the benefit that
the heads will not come down on the
components should those be positioned
incorrectly within the film tube. Any in-
valid product will be rejected and the re-
jection verified – all without any break in
the system’s operation.
The ergonomic control screens and built-
in logic result in more efficient operator
and maintenance training and enable in-
dividual operators to operate the entire
system. Software lockout prevents vali-
dation or traceability from being compro-
mised.
Nothing is left to chance
For applications in the pharmaceutical
industry, all batch codes and expiration
dates need to be verified. To achieve
this, Sigpack Systems uses a Vision Sys-
tem to verify the print on the individu-
ally wrapped blisters and to keep a log of
this process. All wrong data is detected
and triggers the rejection of the product.
Always lead, never follow
Sigpack Systems plays a leading role in
the support of their pharmaceutical cus-
tomers and - as demonstrated with War-
ner-Chilcott – provides support to clients
by keeping their finished-goods supply
chain reliable and secure.
Exhibit at Achema in Frankfurt
At the Achema show, 15 – 19 May 2006,
the customized packaging solution for
Warner-Chilcott will be demonstrated
together with an additional robotic so-
lution for product handling and an inte-
grated top-loader platform for end-of-line
packaging.
The combination of the described system
components represents a highly flexible
and economical system that supports
maximum production efficiency and
operator friendliness.
System Illustration Achema
Her
met
ic B
liste
r
Pac
kage
War
ner
-Ch
ilcot
t
packazine | 25
Adding a new dimension to your
pharmaceutical product
More and more, products must be placed
in the spotlight right at the point-of-sale.
It is very important to dress your prod-
uct appealingly enough to catch the con-
sumer’s attention. The flexible TTLi Top
Loader of Sigpack Systems provides all
necessary options to put your product
into the spotlight. Fancy tray designs, like
displays are simple to apply. The TTLi
integrated Top Loader is built as a cus-
tomized solution, achieving maximum
efficiency within a compact layout. Cod-
ing, labeling, leaflet inserts, and qual-
ity inspection are integrated functions.
The TTLi is the perfect extension of the
Sigpack Systems Flow Wrapper system
in which complementary control and
software elements fuse into a seamless
design.
Convince yourself at the Achema and
witness the system in action!
For more information please contact:
Andreas Graf
Phone +41 (52) 674 6695
Kenneth Hattem
Phone +1 (201) 519-8287
Interview with Jose Carrasquillo, Senior Packaging Technologist of Warner-Chilcott:
What were the main reasons for
Warner-Chilcott to invest in this new
system?
We need additional manufacturing
capacity for the market.
What was Warner-Chilcott looking for
in this system that was so different
from what you did previously?
Warner-Chilcott was looking for a
reliable system with high performance
without sacrificing quality.
What factors went into Warner-
Chilcott’s choice of Sigpack Systems
as a supplier
It was Sigpack Systems experience
with this application. Peace of mind
that we could produce a hermetically
sealed package at the required speed.
Of what value to Warner-Chilcott was
Sigpack Systems‘ ability to deliver a
complete system?
The reason for any client, like me, to
choose a company like Sigpack
Systems is not just for the main equip-
ment, in this case the wrapper, but to
integrate all the ancillary equipment
into a single system and be respon-
sible for the performance of the whole
thing.
TTL
i To
p L
oad
er
26 | packazine Customers & Markets Pharma & Cosmetic
Merckle Biotec is banking on Bosch as a total-
systems supplier for their new syringe-fill-
ing system for pharmaceutical products from
the Ratiopharm Group and for new products,
including biotechnogically derived active sub-
stances. The core of the system is the FLS,
which sets new standards in injection-syringe
processing.
all the way along the line
USM – Machine for detraying/traying of syringes
Time pressure filling system
with fully automatic
in-process control
Interior view FLS in isolator
Precision
A member company of the Ratiopharm
Group, Merckle Biotec’s business seg-
ment is the manufacture of biotech-
nologically derived substances and of
drugs made from these.
The challenge: fewer interfaces
Merckle Biotec aimed to replace an exist-
ing line to stay abreast of the increased
demands for capacity and flexibility in
the production of prefilled syringes. The
challenge lay in keeping the cost of in-
terface clarifications as low as possible
despite the size and complexity of the
project. The crucial factors for placing
the order with Bosch were the convinc-
ing product portfolio covering all the
processing stages and an isolator solu-
tion, which, in effect, is already adapted
to the filling and sealing machine.
The challenge: integration into the
existing space
The next challenge was to integrate the
complex line into the existing building.
Here the space-saving concept of the
FLS machine proved to be of particular
advantage, allowing the machine dimen-
sions to be kept to a minimum despite
the many processes involved.
European premiere: ultrasonic
pre-cleaning of syringes
With the RRU washing machine, an ul-
trasonic cleaning process for syringes is
being brought into use for the first time
in Europe. The syringes travel through a
water bath where they are also cleaned
with ultrasonics. After washing,the sy-
ringes are siliconised to ensure optimum
sliding-in properties for the stoppers.
A tunnel that sterilizes itself
Heat sterilization is the final step before
the syringes are sluiced into the isolator
for filling. Here too Merckle Biotec put its
money on Bosch process know-how and
decided to fit the tunnel with a steriliz-
able cooling section. As a result, repro-
ducible standards of cleanness are guar-
anteed at the critical interface between
the tunnel and the isolator. Another im-
portant step towards even greater
pharmaceutical security!
FLS: Slim. Precise. High-performance.
The core of the line is the FLS filling and
sealing machine, providing numerous in-
novations for the processing of syringes.
The conveyor system reduces the me-
chanical load on the delicate syringes to
a minimum, as all the filling and sealing
processes take place without additional
transfers. The slim design of the machine
also allows workstations to be accom-
modated flexibly at the front and rear,
thus combining functionality with the op-
timum use of space. Yet another innova-
tion used on the FLS are the newly devel-
oped pharmaceutical handling units for a
variety of handling tasks in sterile areas,
featuring simple sizepart changeover and
maximum precision.
Integration instead of interface:
isolator technology and filling machine
from a single source
With the use of a Bosch isolator, Merckle
Biotec receives not only the latest in
Clean Room technology but also a fully
integrated system making the interaction
of operaters, machine and product sim-
pler and more secure than the interface
solutions of various other manufacturers.
Bosch would like to thank Mr Klaus
Berghaus, Head of Sterile Medications at
Merckle Biotec GmbH, for his kind help in
writing this article.
For more information please contact:
Klaus Ullherr
Phone +49 7951 402 517
packazine | 27
Production capacity increase with high
objectives
Astellas Ireland Company Ltd. (formed in
2005 following the merger of Yamanou-
chi Ireland & Fujisawa Ireland) is part of
the Astellas Pharma Inc. which has its
headquarters in Toyko. In order to meet
increased productivity requirements for
the immunosuppressive drug Prograf
(used in transplants), Astellas needed
additional equipment to their existing
Bosch lines. These lines process Prograf
and incorporate extensive measures to
protect operating personnel. When plac-
ing the order for the new equipment
Astellas was therefore interested in a
solution, which increased productivity
while minimizing technical and process-
ing expenditure for operator protec-
tion. To meet those and other objectives
Bosch developed a complete solution
consisting of a capsule filling, machine
plus appropriate peripherals.
Perfect coordination of communication
and planning
The Bosch development plan and the
project communication tools introduced
by Astellas made major contributions to
the completion of the complex line
system on time and within budget. The
customer and the project team had
access to a perfectly coordinated flow
of information during the whole course
of the project. Special customer-specific
machines such as an inspection machine
were combined with “core” machines
represented by the GKF 2500 ASB
capsule filler and a KKE 2500 capsule
checkweigher as well as peripheral
equipment such as product infeed, cap-
sule polisher, drum distributor, convey-
ing units and a metal detector from the
Bosch portfolio were combined to form
a total package. The challenge of com-
bining all components into an ergonomic
and completely automated whole, which
was nevertheless capable of being close-
ly monitored, was achieved to the cus-
tomer’s complete satisfaction. The whole
line is operated from a single user-friend-
ly touch screen, thus reducing operator
intervention (and therefore the associ-
ated security measures) to an absolute
minimum.
Capsule filling and sealing lines from a single source on the march
Astellas Ireland Company Ltd. is banking on the trend to entrust a
single-source supplier with the overall responsibility for the line. The
result is a capsule filling and sealing line operating with perfectly
reconciled modules and requiring minimum operator intervention.
1
Stereoscopic picture:
process steps
2 and 3
Fully automatic
capsule filling line
1 2
28 | packazine Customers & Markets Pharma & Cosmetic
Cooperation brings success
In fact, the agreed-upon project objec-
tives were significantly exceeded thanks
to the outstanding cooperation between
supplier and customer. Project Manager
Rory McSchane (Astellas) was delighted
by the lines extreme efficiency. Its pro-
ductivity exceeds 99.5 %. In addition,
product losses dropped by about 60 %
as a result of improved filling techniques.
Extremely accurate when filling, preci-
sion weighing technology, modern sensor
technology, process control and the use
of the inspection machine have result-
ed in a major increase in product qual-
ity. As well as completing the technical
implementation of the scheme, to sup-
port the commissioning of the line Bosch
also developed extensive validation and
qualification documentation for each of
the line components. The supply pack-
age was rounded off by special operator
training and production support. When
Rory McShane spoke at the Bosch Cap-
sule Symposium he made his enthusiasm
about the success of the overall project
and the collaboration with Bosch clear to
all conference participants.
For more information please contact:
Felix Nink
Phone +49 711 811 57 526
Capsule filling and sealing lines from a single source on the march
from left:
Project managers
Rory McShane
(Astellas Ireland Company
Ltd.) and Felix Nink
(Robert Bosch GmbH)
3
packazine | 29
30 | packazine Customers & Markets Pharma & Cosmetic
Isolators – perfect security
Peak filling quality can be achieved
with an isolator. An isolator uses parti-
tion walls, glove ports, sterile transfer
technology and overpressure to sepa-
rate its aseptic interior from the opera-
tor environment, thus enabling a patho-
gen-free, 3- shift filling operation to be
carried out even over lengthy periods of
time. Recently, progress has been made
with regard to the few disadvantages
of the isolator technique those being
the high initial investment cost and the
time-consuming costly approval process.
Since the publication of the FDA guide-
line “Sterile Drug Products Produced by
Aseptic Processing” in September 2004,
in which the isolator was shown to have
significant advantages over traditional
processing, the approval barriers can
now be more easily calculated. The pro-
cess technology for bio-decontamina-
tion has also become more robust and
reliable. The Bosch bio-decontamination
system, SafeVAP, initially launched in
2003, has set standards in efficiency and
reliability and was approved by the FDA
in 2006.
RABS – with the emphasis on the “S”
An alternative and more flexible ap-
proach to achieve better filling condi-
tions – particularly in existing clean
rooms – are so-called Restricted Access
Barrier Systems (RABS). Depending on
the product and production require-
ments, these are designed as half-open
or closed systems and have either active
or passive air conditioning. Flexibility
therefore begins with the barrier design
itself. But not everything marketed as
RABS is truly a RABS. The system, that is
to say the interplay between the barrier
environment and the handling processes,
has a major impact on the definition. The
International Society of Pharmaceutical
Engineers, working for the FDA and di-
rected by Jack Lysfjord (Valicare, Bosch
Group), therefore proposed a defini-
tion in August 2005, which precisely de-
scribes the barrier applications and the
handling processes for RABS. One clear
statement in the definition is that the
doors of the system must normally re-
main closed.
Bosch installed the first RABS as early
as 1995 on a vial filling line and has ac-
packazine | 31
“Shut the door” for improved quality Barrier systems from BoschPharmaceutical filling machines are traditionally installed in clean rooms
with a high degree of air quality. An alternative is the “barrier system”, with
which the expensive sterile space can be reduced to the filling area itself.
celerated the development of this techno-
logy – in 2002 a new design for a passive
RABS on two powder filling lines was
completed and in 2004 a containment
RABS was installed on a vial line.
In the meantime, many different Bosch
component transfer systems for RABS
have found their way into service (and
approval). Bosch offers a whole range of
possibilities for this purpose, all of which
can be customized to meet local require-
ments.
Effective operator protection with
containment RABS
Containment RABS can be used to pro-
tect operators when filling highly potent
products. A containment RABS has a
closed air circuit, which does not dis-
charge air into the surrounding area.
Depending on the potency of the prod-
ucts, the containment RABS can be
made to be correspondingly airtight and
fitted with a pressure-stage design to
preclude contaminating the environment.
Bosch barrier systems do not imply any
contradiction between product quality
and production flexibility. RABS, as well
as isolators, are an interesting option
for simplified format changes and easier
component transfer. The decisive fac-
tors are exactly matched processes and,
of course, firmly closed doors during the
filling process.
For more information please contact:
Johannes Rauschnabel
Phone +49 79 51 402 452
1 Separation of aseptic area from
operator environment through RABS
2 Powder filling line with passive RABS 3 Mouse hole for separation of infeed and filling
section in a Containment RABS
1 2 3
32 | packazine Customers & Markets Pharma & Cosmetic
High-performance packaging systems for pharmaceutical powders and granulates
Rules and regulations such as FDA 21 CFR Part 11 become increasingly
important, as do technical aspects including weight accuracy, seal
integrity, flexibility in the choice of packaging materials and pack styles,
and line efficiency.
Packaging for powders and granulates
Sigpack Systems supplies vertical sachet
packaging systems to the pharmaceutical
and food industries and with its broad
know-how supports the preparation of
documentation packages such as DQ, IQ,
OQ, PQ or risk analyses.
For an international market BRISTOL
MYERS SQUIBB in Meymac, France,
packs powders for oral application in a
3-shift operation with an RGS/KG3
sachet maker. Up to 1000 sachets per
minute are produced and stacked into
cartons with an integrated cartoning
machine.
Primary and secondary packaging as
system solution
The system includes a 6-lane vertical
sachet machine and an integrated inter-
mittent cartoner, producing 750 sachets
packed into 100 cartons per minute on a
footprint of less than 7.5 m2.
Key technology of the sachet machine
is the patented volumetric filler with
125 cycles per minute. An inline weight-
checking system continually controls and
adapts the dosing volume by regulating
the speed of each respective scroll.
Every sachet is check-weighed online and
sluiced out via a dump gate upon failure
to meet the defined plus/minus weight
tolerances. The pivotable dosing module
provides excellent access for cleaning
and maintenance.
Securely sealed tight seams are of funda-
mental significance particularly for
pharmaceutical products. Web preheat-
ing and escorting cross-seam sealing
units guarantee sachets with seal
integrity at high cycle rates and warrant
Modular design
packazine | 33
the requisite flexibility with regard to
packaging materials.
The integrated cartoning machine oper-
ates at max. 100 cycles per minute and
excels with high size flexibility and short
changeover times; the KG3 offers plenty
of space for inserting booklets or inserts
while coding units, code readers and
checkweighers may easily be integrated
as well.
Control philosophy, Management
Information System, FDA 21 CFR
Part 11
The PLC-controlled system operates with
a single 12” colour touchscreen on which
production parameters are adjusted
and displayed. Based on the Siemens
S-7 400 PLC, the 21CFR Part 11 require-
ments are fully met, including audit trail,
password management or user identifi-
cation.
The individually designed Management
Information System (MIS) provides de-
tailed data analyses, evaluations and
statistics. The installed server system
ensures data transfer to the provider
network.
Training, Validation, Life Cycle
Management
Bosch Packaging offers individual train-
ing programs and provides excellent
support for qualification and validation:
training courses from Classroom to On-
the-Job and interactive Computer-based
Training offer customized methods and
modules for specific requirements. A
broad service platform, E-business solu-
tions for ordering spare parts and in
logistics stand for lean processes and
conserve resources.
For more information please contact:
Holger Botsch
Phone +41 52 674 89 28
1
2
3
1 RGS
2 Sealing module
3 Pouch insertion
34 | packazine Customers & Markets Pharma & Cosmetic
Packazine: Novartis International AG is a
big player in the pharmaceutical industry
with $32.2 Billion USD in sales and near-
ly 91,000 employees. What is Novartis
Horsham’s role within Novartis?
K. Hill: On the Novartis Horsham site
there are four divisions: Technical Op-
erations (PharmOps), Novartis Consum-
er Health, Research and Development.
The site being the centre of excellence
for respiratory diseases. Pharma Ops
makes solid dosage tablets, the majority
of these going into blister packs, while
some are bulk-shipped in containers.
Novartis Horsham employs approx 1,000
people, 325 of whom are working for
PharmOps.
Packazine: In 2002, Novartis Global initi-
ated this project to standardize the pack-
aging of pharmaceutical solids. Among
six potential suppliers Bosch was se-
lected as the most suitable for this pro-
ject. Would you please tell us about this
project?
K. Hill: This project was initiated to de-
velop a standard machine that could be
universally accepted across the Novar-
tis plants in the context of the global ra-
tionalization and standardization of the
blister packs.
Packazine: What was your role in this
project?
K. Hill: I was as representative for the
Horsham plant involved in the initial user
requirement specification (URS) for the
cartoning machine. We worked out the
blueprint of basic and optional require-
ments for the ideal cartoning machine.
Packazine: What does this project mean
to Novartis Horsham?
K. Hill: In Horsham we ran our own
project of harmonization. Obviously we
had certain constraints because the
existing equipment which had limitations
in complying with some of the harmoni-
zation standards due to tooling
constraints. When this project was initi-
ated we grabbed it with both hands be-
cause we saw the benefits in improved
productivity.
Packazine: The project was challeng-
ing with many product and site-specific
items. How did you organize all this in
the project phase?
K. Hill: We knew from the start of the
project exactly what our site-specific
requirements of the equipment were. We
set up a cross-functional project team, a
project plan and a detailed action plan.
The team evaluated each particular mod-
ule of the line. All items were then cross-
checked with the Bosch team to ensure
complete clarity and understanding,
nothing was left to interpretation.
Three months before FAT we implement-
ed a ‘Fast Action for Results workshop’
(FAR) in the plant. A cross-functional
group of people who would be working
with the Bosch line once it arrived, brain-
stormed all the potential issues they felt
they would face and set about an action
packazine | 35
Flexibility counts. Blister line successfully installed at Novartis, UK
Kevin Hill, Manager of project engineering at Novartis, Horsham,
gives us an inside view of the project at Horsham to harmo-
nize packaging formats, coupled with the new installation of the
Bosch blister packaging machine.
plan on how to deal with them. This ful-
filled another agenda which was to intro-
duce and engage all people working with
the machine as early as possible, certain-
ly before it arrived.
Packazine: In your opinion, how did
Bosch deal with your specific require-
ments?
K. Hill: In my opinion our project was
handled very professionally. All of my
project team have worked very well with
the Bosch team. For us it was a working
partnership, which was very good. We
are very pleased so far with our experi-
ences with the machine. There are still a
number of items that have to be resolved
but we are working with Bosch to re-
solve them.
Packazine: Where did you see the key
success factors?
K. Hill: First of all, the success came be-
cause the Novartis team was always well
prepared and very interested in the new
technology. Also, more importantly was
the regular communication between the
Horsham Novartis team and the Bosch
team. We agreed to have at least once a
week a telephone conference with the
Bosch team to discuss the action plan so
that the project stayed on track. We also
had regular site visits with face-to-face
discussions, checking on progress and
last but not least getting into the neces-
sary detail of the machines functionality.
This took a lot of hours work but at the
end led to a successful result within the
original time schedule.
Packazine: Your blister line processes
Alu/Alu blisters, Triplex film, as well as
standard PVC/Alu blisters. One of your
products is a hard gelatine capsule that
only weighs 12mg. The cartons are sup-
plied either with or without an inhaler.
How do you evaluate the blister line in
terms of flexibility and product change-
overs?
K. Hill: The flexibility of our medium
speed machine is good. So far we have
only used part of the machines capabili-
ties but we believe we are equipped to
Kevin Hill,
Manager of project
engineering at
Novartis Horsham
New developments introduced sucessfully
Basel, 03/14/2006: Novartis
releases four further high-speed
blister lines out of the Preferred
Supplier Agreement with Bosch.
These will be placed in various euro-
pean manufacturing sites. With this,
the total number of new Bosch in-
stallations at Novartis in Europe and
the US increases to 14.
36 | packazine Customers & Markets Pharma & Cosmetic | Other Markets
tackle further challenges should they
arise. The machine is user-friendly and
can be easily adjusted.
In terms of changeovers it is difficult to
put a fair assessment on it because the
number/types performed have been
limited due to the planned phasing of
moving more products onto the machine.
To date we have predominantly run the
alu/alu packs on the machines.
Packazine: How do you find the pharma-
ceutical production security of the line?
K. Hill: We had very high expectations
concerning the security of the line and
the line met all of them. For example
with our existing camera systems we
had several difficulties to recognize one
of our products on aluminum foil. It is a
transparent capsule with very little
powder in it. We had up to reject 3 %
good blisters on the old equipment. With
the new camera system we could tighten
the tolerances significantly down and
reduce the number of rejected good
blisters to less than 1 %.
Packazine: Please tell us about your
experiences with the Bosch training
program.
K. Hill: We had an initial week of training
for the operators and engineers when
the machine arrived in the plant. We then
had a refresher week of training about 6
weeks later. This was finally followed up
by a visit from one of the Bosch design-
ers to explain the design concept of the
machine. We wanted the designer go
through the design concepts of the
equipment as this underpinned our tech-
nicians understanding and aided faster
solutions when fault finding.
The overall impression of the training
was very good and the operational team
were very pleased with what they had
received.
Packazine: Mr. Hill, thank you for this
positive feedback! We wish you and your
team continued success in the
future.
For more information please contact:
Katja Vollmer
Phone +49 711 811 576 37
Since September 2005 Novartis, Horsham runs a Bosch blister line TLT2800/CTC with an inhaler feeder,
a Bosch checkweigher, a Neri labeler, Pester bundler, casepacker and palettizer.
packazine | 37
New customer-specific training courses
The Bosch Pharmaceu-
tical Training Depart-
ment in Crailsheim has
been regularly sup-
porting customers with
multilingual courses
on complex areas of
technology. The main
themes are the depyro-
genation tunnel, time-
pressure filling sys-
tems and automation
systems.
Technical enhancement courses for
training in complex areas of technology
increase the pharmaceutical training
portfolio
In-house courses are also available on
request; in these courses on-the-spot
training is provided in small groups and
answers to customer-specific questi-
ons take center stage. This fall we will
extend the range to include our cap-
sule filling machines, focusing on pro-
cess optimization, malfunction search,
preventive maintenance and automati-
on. Perfect customization of all training
courses enables us to provide made-to-
measure training on all the customer’s
Mo
du
les
focu
sed
on
tar
get
gro
up
Kn
owle
dge
& D
eman
ds
Operation
MaintenanceMechanical / Electrical
Automation
Validation
38 | packazine Customers & Markets Other Markets
business areas. Machine operators, tech-
nical support staff, automators, Enginee-
ring and Validation and/or Quality De-
partments are given optimal step-by-step
introductory training, start-up support
and on-the-job training as part of a pro-
duct system change.
Ongoing support with machine-specific
training systems.
Support is also provided in the form of
complete training systems over the en-
tire lifecycle of a machine. The training
is optimally introduced into the project
timetable and consists of training manu-
als, presentations, multimedia modules,
train-the-trainer courses and final qua-
lifications. This variety also allows us to
develop blended-learning concepts. The
tailor-made training products and techni-
cal enhancement course enable you and
your staff to “brush-up” on and conti-
nuously extend your technological skills.
Our staff, who are specially trained for
the pharmaceutical industry, look for-
ward to presenting your individual trai-
ning solution to you.
For more information please contact:
Günter Lieth
Phone +49 7951 402 481
The
Pro
duc
t C
on
cep
t – „
The
way
we
live
trai
nin
g“
Multimedia
On-the-job
Classroom
Initial
Course Refresher Top Up
Technical
Enhancement
Train-the-
Trainer
Technical Training
System
CBTComputer
based training
packazine | 39
100 years of innovationin the service of packaging
From machine manufacturer to system provider – this year, the Swiss
machinery manufacturer Sigpack Systems AG looks back on more than
one hundred years of company history.
It all began in 1906
when the company, called Schweizeri-
sche Industrie Gesellschaft (SIG – Swiss
Industrial Company) at that time, built
the first packaging machines as subcon-
tractor for an external patent-holder, one
of the founders of Sapal S.A in Ecublens.
These modest table-top machines were
hand-operated but already replaced the
many complicated hand movements
needed to fold wrapping materials. The
result was the simplification of packag-
ing chocolate and soup cubes.
The move to automated packaging at
break-neck speed
In 1921 SIG commenced the develop-
ment and manufacture of its own pack-
aging machines, which could now also
be used for different foodstuffs such as
biscuits and butter. By 1938 the com-
This is what the first hand-operated die fold
machine looked like. It packaged up to 25
Napolitaines per minute and weighed
app. 150 kg. The price at the time was
760.– CHF that would make it a blockbuster
nowadays!
40 | packazine Customers & Markets Other Markets | Events
Everything in one stop - creative and innovative packaging solutions have turned Sigpack Systems
into one of the leading system providers.
pany was producing 26 different types
of machines, and when the year 1981
arrived the range had been extended to
include over 60 types of machines. With
the onset of an all-out boom in automat-
ed packaging in the 1950s, SIG stood
head and shoulders above its competi-
tors when, in 1956, it launched its first
continuously operating horizontal form
fill and seal machine.
A string of successful innovations of
this type continued right up to the pres-
ent day. In 2005, the range included
the compact HCM system platform for
horizontal form fill and seal machines,
the TTLi integrated top loader, the new
WTI tray loader and the RA/KG4 stick
pack machine.
Global market presence
Although the earliest packaging ma-
chines produced by SIG were mainly
delivered to Swiss chocolate manufac-
turers, exports now account for 97 % of
SIG production each year. As part of the
increase in production capacity, the com-
pany left its original location in Switzer-
land’s Neuhausen in 1964 and moved in-
to a purpose-built factory in neighboring
Beringen. In 1999 Sigpack Systems be-
came an independent strategic business
unit within the SIG Pack Division.
Full-range provider of packaging tech-
nology
With the take-over by Bosch Packaging
Technology on July 1, 2004, the Sigpack
Group became part of the world’s fore-
most supplier of packaging technology.
Bosch’s leading position is ideally sup-
plemented and supported by the innova-
tive packaging machines and systems of
Sigpack Systems AG and its almost 600
employees.
As part of the centennial celebrations
of Sigpack Systems AG, an Open Day, a
Customer Day and a Staff Day will be
held in June 2006 in Beringen.
For more information please contact
Brigitte Salm
Phone +41 52 674 74 56
A glance into the SIG packaging
machine assembly shop in its
early years.
packazine | 41
Events 20062006 Trade Show Location Industry
15.05. – 19.05. ACHEMA Frankfurt Pharma
17.05. – 19.05. Interphex Tokio Pharma
20.05. – 23.05. National Pharmaceutical Expo Zhenghhou Pharma
28.05. – 31.05. iran food and drinktec (agrofood) Teheran General
06.06. – 09.06. Fispal São Paulo Food
19.06. – 23.06. Rosupak Moscow General
27.06. – 30.06. ExpoPack Mexico General
11.07. – 13.07. ProPack China Shanghai General
14.08. – 17.08. Embala Nordeste Recife Food
01.09. – 04.09. India packaging Show New Dehli General
September I.I.E.C. Iran Teheran Food
05.09. – 08.09. Bio Farmaceutica Mexico Pharma
06.09. – 07.09. Pakex Ireland Dublin General
12.09. – 14.09. Food Tech São Paulo Food
13.09. – 15.09. Müllereitagung Detmold Food
16.09. – 20.09. Taropak Posen General
18.09. – 22.09. MSV Brünn Pharma
19.09. – 22.09. Tecno Fidta Buenos Aires Pharma
26.09. – 28.09. FachPack Nürnberg General
26.09. – 28.09. PPMA Birmingham General
03.10. – 06.10. Macropack Utrecht General
09.10. – 13.10. Agroprodmash Moscow Food
20.10. – 22.10. Pharm Expo Mumbai Pharma
24.10. – 27.10. Scanpack Göteborg General
24.10. – 27.10. ETIF Buenos Aires Pharma
29.10. – 02.11. PackExpo (PMMI) Chicago General
07.11. – 10.11. Fispal Recife Recife Food
07.11. – 10.11. China Pharm Shanghai Pharma
08.11. – 09.11. CME Shanghai Food
Customer magazine of the Packaging Technology Product Division Robert Bosch GmbH
Editor in ChiefCentral MarketingPhone +41 (52) 674 [email protected]
DesignBOHNER.concept · agency for creative communication & design
PicturesOtlinghaus Fotodesign, Inge Zinsli Werbefotografie, Bosch Packaging Technology
PublisherProduct Division Management, Stuttgarter Straße 130, D-71332 Waiblingen© Copyright · Packaging Technology Product Division Robert Bosch GmbH
The contents of this publication may not be reprinted except by permission. Subject to alterations.
Imprint
packazine
SWEEPSTAKESTell us what you think of our packazineWin an iPod or a Bosch IXO cordless screwdriver
Company stamp or address
Dear packazine Reader,
Please complete the questionnaire and fax it back
to us at +41 (0)52 674 6350 or visit our website
www.bosch.com/pa
Suggestions and Criticisms
EligibilityIt is not required to complete the questionnaire in order to enter the sweepstakes. The sweepstakes are not open to employees of the
Robert Bosch GmbH or their families. The drawing is not open to the public, winners will be notified in writing. There is no cash alternative,
and no exchange is possible. The sweepstakes deadline is 30 June 2006. Any legal recourse is excluded.
Thank you very much for your help and good luck in the raffle !
The packazine Editorial Team
Contact person
The packazine FormatPlease grade us from 1 (= very satisfied) to 6 (= dissatisfied)
Reasons / Comments
Photos / graphics
Size
Subjects covered
Information content
1 2 3 4 5 6
packazine CategoriesPlease grade the following categories from 1 (= highly informative) to 6 (= uninteresting)
News
Food and Confectionery
Pharmaceutics and Cosmetics
Other markets
Reasons / Comments1 2 3 4 5 6
Two issues a year are...
Number of readers per issue in your company:
Did you already read articles on our website www.bosch.com/pa?
In what form would you prefer to receive the packazine?
too few OK too many
1 2–3 4–7 > 7
Yes No
Printed Electronic
There are a total of
3 iPods and 10 IXOs
to be won
packazine | 43
Bosch like you have never seen before.
Bosch Packaging is well known for filling and packaging of vials, ampoules, cartridges and bulk syringes. It is with this extensive knowledge and experience that Bosch now introduces a new product line desig ned specifi cally for nested syringes. With quality and innovation in mind, Bosch is introducing a complete portfolio of nested syringe fi lling and packaging equipment. You can expect all of the same great quality, effi ciency, high performance and support as Bosch Packaging offers with our other equipment.
www.bosch.com/pa
MA
CH
sujet_18.indd 1 30.3.2006 16:13:59 Uhr
Locations worldwide Bosch Packaging Technology
Brazil Bosch Sigpack Tecnologia de Embalagem Ltda.Avenida Jurua 606AlphavilleBR-06455-010 Barueri-SPwww.bosch.com.brTel. +55 11 21 17 68 00
ChinaBosch Packaging Technology(Hangzhou) Co. Ltd.391 Wen Er Road Bld. 3Hangzhou High-Tech ZonePRC-310012 Hangzhouwww.bosch.com/paTel. +86 571 88 93 55 26
DenmarkMøeller & Devicon A/SLanggade 43DK-4262 Sandvedwww.m-d.dkTel. +45 55 46 24 00
FranceBosch Techniques d’Emballage S.A.S.Rue de I’Industrie 1F-67116 Reichstettwww.bosch.com/paTel. +33 3 88 20 98 10
Sigpack S.a.r.l FranceBel Air Building58 rue Pottier78150 Le Chesnaywww.sigpack.comTel. +33 1 39 23 01 84
GermanyRobert Bosch GmbHPackaging Technology Stuttgarter Strasse 130D-71332 Waiblingenwww.bosch.com/paTel. +49 71 18 11-0
Robert Bosch GmbHPackaging Technology Blaufelder Strasse 45D-74564 Crailsheimwww.bosch.com/paTel. +49 79 51 40 21
Robert Bosch GmbHPackaging Technology Kölnische Strasse 1–3D-41747 Viersenwww.bosch.com/paTel. +49 21 62 24 80
Makat Candy Technology GmbHFeldstrasse 52D-56269 Dierdorf/Wienauwww.makat.deTel. +49 26 89 94 34-0
Great BritainBosch Packaging Services Ltd.Unit 2A, Meteor Business ParkMeteor Centre, Mansfield RoadGB-Derby DE21 4SUwww.sigpack.comTel. +44 13 32 62 62 6
IndiaMotor Industries Co. Ltd.Packaging Technology DivisionRMB Complex, Hosur Road, AdugodiIND-560 030 Bangalorewww.bosch.com/paTel. +91 80 2299 2033
Japan Bosch Packaging Technology K.K. 3-6-7 Shibuya- kuJ-150-0002 Tokyowww.bosch.co/jp/packagingTel. +81 35 46 62 55-0
Bosch Packaging Services K.K.2-2-2, Nishiura, Funabashi-CityJ-273-00 17 Chiba www.bosch.co/jp/packagingTel. +81 4 74 35 25 74
Bosch Packaging Technology K.K.Shin-Osaka Daiichiseimei Bldg. 4F3-5-24 Miyahara, Yodogawa-kuOsaka 532-0003www.bosch.co/jp/packagingTel. +81-6-6391-4641
NetherlandsRobert BoschVerpakkingsmachines B.V.Industriekade 43NL-6001 SE Weertwww.bosch.com/paTel. +31 49 55 74 000
Tevopharm B.V.Packaging Technology DevisionConradstraat 4NL-3125 BC Schiedamwww.bosch.com/paTel. +31 10 48 85 899
RussiaRobert Bosch GmbHPackaging Technology DivisionOffice: Rexroth HeadquarterSchelkovskoye Chaussee 100, 11.floor RUS-105523 Moscowwww.bosch.ruTel. +7 95 99 53 21-0
SwitzerlandSigpack International AGRheinstrasse 36CH-8212 Neuhausen am Rhf.www.sigpack.comTel. +41 52 674 65 00
Sigpack Services AGA Bosch Packaging Technology CompanyIndustrieplatz 1CH-8212 Neuhausen am Rhf.www.sigpack.comTel. +41 52 674 75 74
Sigpack Systems AGIndustriestrasseCH-8222 Beringenwww.sigpacksystems.comTel. +41 52 674 77 77
Sapal S.A.44, Av. du Tir-FédéralCH-1024 Ecublenswww.sapal.comTel. +41 21 633 52 00
Transver AGZürcherstrasse 42CH-8852 Altendorfwww.transver.comTel. +41 55 451 88 88
Demaurex S.A.Chemin des Mésanges 3CH-1032 Romanel-s/Lausannewww.demaurex.comTel. +41 21 644 25 00
SingaporeBosch Packaging Technology Pte. Ltd.31 Tannery Lane # 04-01SGP-347788 Singaporewww.sigpack.comTel. +65 6746 06 00
USABosch Packaging Technology NAFood and Confectionery Divison9890 Red Arrow HighwayUSA-MI 49106 Bridgmanwww.boschpackaging.comTel. +1 269 466 40 00
Bosch Packaging Technology NAPharma Division8700 Wyoming Ave. NUSA-MN55445-1836 Minneapoliswww.boschpackaging.comTel. +1 763 424 47 00
Doboy Inc.869 South Knowles AvenueUSA-WI-54017 New Richmondwww.doboy.comTel. +1 715 246 65 11
Bosch Packaging Services Inc.2440 Sumner Blvd.USA-NC 27616 Raleighwww.sigpack.comTel. +1 919 877 08 86
www.bosch.com/pa E-Mail: [email protected]