combo feeder - vimachem.com · 2-technical details 2-1- fundamentals. y. z. x. the combo feeder is...

COMBO FEEDER Handbook

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

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).

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.

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.

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

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.

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

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

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

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

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

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…

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

pocket

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.

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

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

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.

COMBO FEEDER

Transparent cassette with Brushes

Handles

Removable lid

Feeding chute

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.

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

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

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

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

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

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

COMBO FEEDER

3- EXAMPLES OF CURRENT INSTALLATIONS

On a Servac PH3

On an Ima C60

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

combo feeder - vimachem.com · 2-technical details 2-1- fundamentals. y. z. x. the combo feeder is...

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