Innovations for fast, flexible processing
Romaco will emphasise its status as one of the pre-eminent suppliers of processing and packaging equipment for the pharmaceutical and cosmetics sectors at Achema 2003, launching a number of products designed to address the challenges faced by these sectors.
For the first time at Achema, all Romaco equipment will be united on a single stand, so that the true extent of its equipment range will be apparent.
Roto Cube: the complete one-step granulation and drying unit
Romaco Zanchetta will be launching a new vacuum granulator-dryer. The Roto Cube features impressive core processing technologies combined with excellent ergonomics, high GMP compliance and a compact footprint.
The machine represents an all-in-one granulation solution, with previously peripheral functions - such as granule calibration - incorporated within the production unit. Connections such as the vacuum line are also now integrated, to form a remarkably compact complete package.
The latest developments in electronic technology and sensors are used throughout. As with other systems in the Roto range, the Roto Cube is a 'one-pot' processor, making it ideal for high containment applications. The processing bowl is mounted on a novel hoist system, so that its height can be varied. During processing, for example, a low level ensures easy access to the sight glass for a quick visual check of progress. When product is ready for discharge, the bowl can be raised to give perfect matching of the discharge valve to the inlet on an IBC. And when maintenance is required, the bowl can be raised or lowered so that all areas can be accessed. This feature means that there is no longer any need for either a working platform or an access pit.
The machine is designed for through-wall installation, with only the bowl itself and the hoist located within the clean area, thus keeping the amount of cleanroom space required to a minimum. Further, the lid opens laterally (hinged left or right), so that no allowance for clearance is necessary; its design also eliminates dead areas for improved product quality and yield, as well as simplified cleaning.
The Roto Cube is an integrated system, with all the required components located 'on board'. This assures quick and easy set-up, as well as limiting the floorspace required in the technical area.
Dinex vacuum processing plant
Romaco FrymaKoruma will launch a new high-end vacuum processing unit for the pharmaceutical and cosmetics sectors. Appropriate for semi-solid products such as suspensions, emulsions and gels, the Dinex features a number of innovations. The Dinex is a one-step processing system offering advantages such as short batch times, high containment and a compact footprint. Of particular interest is a newly designed homogeniser. This operates on the proven rotorstator system but with the added benefit of axial adjustment of the stator. The ability to adjust the shear force exerted on the product in this way gives optimum flexibility in matching the process to the requirements of the product. When the stator is placed in the shearing zone, the machine produces perfect dispersing with good pumping characteristics. When the stator is placed outside the dispersing zone, the machine offers excellent pumping characteristics at a lower shear force, process parameters which are ideal for sensitive products.
The agitation system inside the main vessel is also novel. It incorporates a helical ribbon agitator, which allows the direction of product flow against the vessel walls to be aried upwards or downwards, depending on the direction of rotation. Thus the user is able to vary the parameters of the mixing process to maximise product quality. The agitator also includes conical mixing nozzles, which produce a horizontal and vertical macro mixing action. These, combined with the action of the helix, produce optimum mixing - even for the most viscous products - with short batch times and rapid heating and cooling, where a double-jacketed vessel is supplied for this purpose.
The Dinex also allows both internal and external recirculation of the product - a further contribution to process flexibility. Internal recirculation allows feeding of the product beneath the fill level in the main vessel, a particular advantage where batch sizes are small. External recirculation complements the internal vertical mixing action.
A streamlined and cost-effective installation is ensured by the fact that no additional pumps are required for either the Clean-in-Place (CIP) or discharge functions.
Noack 623 multi-stroke blister machine
Romaco Noack will launch an important addition to its 623 range of platen-sealing blister packers at Achema 2003. The Noack 623 MS borrows technology from its rotary-sealing counterpart, the Noack 900, to give increased throughput of up to 400 or even 600 blisters per minute.
The working principles are the same as the standard 623, with the exception of the die-cutting station, which now features a multi-stroke execution. The number of forming cycles per minute remains at 70 (except PP Mono Blisters = 50) but the die-cutting cycles have increased from 70 to a maximum of 200 per minute. The 230mm web width means that the standard layout for blisters is one or two across the web, with blister exit at 90 degrees to the web direction. This makes the 623 MS a true 400-per-minute machine for 110mm blisters.
Where blisters are produced for bulk, the machine can produce up to 600 blisters per minute, each with a maximum length of 70mm
The die-cutting area is a new module based on the Noack 900 system and includes a loop and indexing roller. Two new servo motors have been added, to drive the indexing roller and die-cutting station respectively. This feature enables the storage of formats for faster changeovers and guarantees smoother foil transport.
Particularly significant with regard to changeover times is that the new die-cutting station can be changed over without the use of any tools, saving an estimated fifteen minutes compared with the standard 623.
Promatic P91 flexible intermittent motion cartoner
The P91 is the latest addition to Romaco Promatic's range of intermittent motion horizontal cartoners and has a flexible, modern GMP balcony design and competitive pricing.
The P91 has an output of up to 90 cartons per minute, with dimensions of 15-120mm, 12-80mm and 55-200mm (A-B-C). Its modular design allows flexible configuration of the feeding group, to make it appropriate for the product at hand and assure reliable feeding. The design also accommodates ancillary equipment, such as leaflet feeders. In terms of products handled, the P91 is extremely versatile.
Positive and forced carton opening assures control and therefore reliable handling of all components.
Much attention has been paid to the design of the P91. In terms of GMP compliance, high visibility and the absence of areas where stray product might collect are significant. Operator ergonomics are excellent, with a simple design facilitating fault-finding and easy access to all areas of the machine thanks to the 'walk-in' guarding. The machine is also compact, at three metres in length.
The machine is PLC-controlled, with a modern, user-friendly interface in the form of a touchscreen panel. The ability to store and recall formats and to complete adjustments without the use of tools limit downtime at changeover to the absolute minimum. At Achema, the P91 will be shown in line with a Macofar LVI liquid filler.
Laetus IVT: secure monitoring of market-specific labels
Following the introduction of new legislation in November last year, it has become compulsory to use a special vignette label for pharmaceutical products supplied to the Italian and other markets. The scheme - whose objective is to reduce fraud - poses various challenges for manufacturers, including the requirement to read consecutively-numbered labels. A collaboration between Romaco Laetus and Italian security printer and labelling machine manufacturer Arca, has produced a system to meet the new requirements without compromising productivity.
Named IVT (International Vignette Tracking), the system consists of proven components such as Laetus code cameras, laser scanners and the Commander 15 industrial computer, combined with the ARCA-log software package, already proven in other sectors. Its particular appeal lies in its modular design, comprising sections relevant to each stage of the packaging operation. The design also allows flexibility for future upgrades.
The Italian Government's initiative was prompted by a need to meet new obligations in the area of pharmacovigilance imposed by the EU. Other Member States using the vignette system for reimbursement are currently considering the options for compliance.
Hall 3.0, Stand L22-N31