Detailed Product Description

OPERATION:

This machine is fully automatic & based on PLC controlled operation. The sequence of operation takes place as under.

Once the operator starts the machine, he needs to check & suck the material from storage tank to nozzle end without air. For that the machine is equipped with special Priming facility. Moreover this facility is also useful to clean the filling line from storage tank to nozzle end (clockwise) & nozzle end to storage tank (anti-clockwise) very quickly. In short, this facility is useful to carry out on-line CIP / SIP process.  The priming can also be done individually for all the pumps.

Then the pumps are calibrated to set the desired volume by using Pump calibration system. The calibration of pumps (desired volume) is set into 4 steps, viz- filling RPM, filling time,     suck-back time & suck-back RPM.

The process of nitrogen flushing PRE or POST is then set. The PRE flushing time must be set prior to filling & at the time of diving of nozzles from top to bottom. The POST flushing time must be set immediately after filling & at the time of lifting of nozzles from bottom to top.

After achieving desired filling volume with nitrogen flushing, the operator can then start the machine by starting both the AC drives of conveyor & turntable. The speed of conveyor & turntable is synchronized with PLC. Here, operator needs to set desired speed of machine.

The process of filling & conveying takes place simultaneously through the motion filler system.

The filled vials then passes through the bung disc for the process of bunging. This disc is also synchronized with the speed of the machine. The bung passes smoothly through specially designed vibrating bowl & chute. Operator only needs to switch ON the bunging system. The bungs are then placed & pressed on the vials.

Then, the filled & bunged vials are collected in tray OR passed to on-line sealing machine. through turntable.

In short, the whole machine operation - feeding of bottles, filling, nitrogen flushing & bunging & collection is synchronized. There is no need to adjust any parameters separately.

The machine consists of main structure with safety glass doors, facility of mounting L/F, in-feed turntable, diving filling head with 4 separate pumps, conveyor with rolling system (motion filler), out-feed turn table, vibrator bowl for bung, vibrator for chute, vacuum disc for bung placement & PLC touch screen, transformer, AC drive & genuine pneumatic components.

SALIENT FEATURES:

The unit is made compact & versatile as per GMP norms.

The contact parts are made of Stainless Steel 304.

Rigid vibration free construction for trouble free performance.

The contact parts such as filling nozzle, bung disc are made of SS316

The pharma grade silicon tubes are used for filling & CIP/SIP.

Easy to clean the base of the machine.

There is a special feature called PRIME which is useful to suck the filling material from storage tank to nozzle end very quickly. Moreover this facility is useful to clean the filling line (silicon tubes) as well as filling pump in both the directions.

The machine has a facility of using PRIME function for all the pumps together or individual pumps also.

The process of filling is done by specially designed filling pump which can serve the purpose of CIP & SIP.

Individual pumps can be adjusted & calibrated for the desired volume by use of easy to operate PLC

Oil based material can also be run easily without dripping because of specially designed pump with the facility of suck-back.

The each filling head can work independently & hence machine works continuously without sacrificing major production.

No change parts are required for different size of vials as well as different filling volume.

There is a very less product change over time due to very less usage of mechanical parts such as syringe set, Teflon seal, gear & chain etc.

Easy to operate PLC for any kind of volume adjustment or speed adjustment

Synchronized motion filler for smooth filling purpose

Specially designed bung oriental bowl & discharge chute with in-built vibrator. The bung oriental bowl & chute are teflon coated for use of wet bungs.

Bungs are hold in the specially designed vacuum bung hold disc & the same disc discharge the bung uniformly on the vial. The bung pressing roller presses the bungs uniformly.

The same bunging assembly can also be utilized for half stoppering.

For different heights of vials, the whole assembly can be moved upwards & downwards.

Alarm alerts through PLC for No vial, Machine stop & No vial, No bung.

Production counter is given with password protection for daily track report and planning for the same.

The faults can be detected on the PLC touch screen and can be attended easily for the same.

The machine is supplied with isolated power supply to avoid adverse effect of electric supply.

The output speed can be appeared on PLC screen and adjust the same as per appropriate requirements.

Very less mechanical adjustment required due to the special design.

User friendly and very less maintenance required.

Nitrogen facility (Pre or Post) can be provided as an OPTION

Motion Filler for continuous filling. No stoppers.

Unique design of rolling conveyor

Easy loading of vials to in-feed turntable - by loading tray

For smaller vials, the speed of turntable can be set individually.

Most reliable & proven mechanical components such as FESTO make pneumatics & CE certified electrical/electronics such as Bonfiglolie make AC motor, Delta make drives, PLC & HMI Touch screen, Sensors, MCBs, relay etc.

The construction of machines electrical panel is in line with the IP 55 standard.