Weigh systems

When AstraZeneca needed to reduce downtimes in one of its high volume production units, it turned to Mettler Toledo to provide an innovative weighing and data recording system

AstraZeneca's site in Macclesfield, Cheshire, has seen a programme of continuous investment since it was established in the 1960s and now has more than 3,000 employees.It is the second largest manufacturing and supply site in AstraZeneca.

It is also a Quality Assurance Lead Site, making it responsible for the quality control and assurance of a range of products. The site has facilities for all three stages of pharmaceutical manufacture - bulk drug manufacture, formulation and packing.

good relationship

One of Macclesfield's high volume tablet production facilities was experiencing considerable downtime when changing the sealed membrane on the original platform scales; also data records were not available.

Following a site visit, a new weighing system - consisting of a DN1500 platform scale, ID7 weighing terminal and GA46 printer - was recommended to replace the older equipment.

AstraZeneca chose Mettler Toledo as a successful relationship has developed between the two companies. The company is now AZ's preferred supplier and its equipment is now standard on site. Graham Patten, project engineer, explains the company's decision: 'The Tablet Processing Facility (TPF) project that I have been involved in was an upgrade. One of the prerequisites was to provide a further 15 years' operation and Mettler Toledo could offer this support.

'The processing plant already uses DN1500 scales and the ID7s are an upgrade to the 8510 display. Numerous ID7s have been installed throughout two new processing facilities built in the last three years, and they provide the additional functionality needed to link to other process equipment, such as Ethernet cards.'

The equipment is being used to weigh various ingredients for drug manufacture, explains Patten: 'The scales are used throughout the TPF during the dispensing of raw materials in addition to weighing the product at various stages of the manufacturing process. The weights are then recorded - essential for the reconciliation of product during the process.'

The ID7 terminal offers a rugged stainless steel design and IP68 protection against dust and water ingress, and the terminal, available in bench, wall or panel mount, can be connected to up to three scales, two of which can be an analogue weighing platform.

A wide variety of applications are possible using integral software 'Pacs', which extend the basic weighing functions into areas such as counting, formulation, dispensing, totalling or checkweighing.

data entry

Data can be entered via the terminal, a plug-in alphanumeric keyboard or by using a barcode scanner. As part of the weighing system the company purchased GA46 printers - fast thermal printers with integrated RS232 data interface for connection to all ID-operating terminals.

'GA46 printers have been installed where systems are not hooked up to SCADA type systems to record and print weight data. They are used to provide printed evidence of quality critical stages during the manufacturing process.'

The installation has provided an audit trail as well as meeting hygiene requirements - it now takes only half an hour to clean the area instead of a few hours. It has also reduced equipment downtime and the engineers have to spend less time on calibration.

Patten adds: 'We have gained additional functionality for the ID7s that will be utilised as processes become more complex.'

service agreement

AstraZeneca has invested in a complete range of after sales service agreement options designed to complement existing quality systems. Tracey Johnson, marketing and customer development - service for Mettler Toledo explains: 'AstraZeneca's Gold+ service agreement has been specifically designed to meet its individual requirements.

'We respond to site within a guaranteed eight working hour timeframe, ensuring limited interruption to the production process.

'As well as supporting the above equipment, AstraZeneca has a range of TotalCare 21 service agreements covering both Mettler Toledo and other manufacturers' equipment across its Macclesfield site,' concludes Johnson.