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Bosch debuts flow wrapper for packaging individual vials in North America

Bosch debuts flow wrapper for packaging individual vials in North America

October 17 2014

Bosch debuts flow wrapper for packaging individual vials in North America

PACK EXPO 2014

  • Hermetic packaging for excellent product protection
  • High-speed separation of vial cards
  • High degree of process reliability due to integrated inspection units
  • Save gas and production costs thanks to the new RT-MAP system

Sigpack HCUL horizontal flow wrapper

Packaging up to 300 single blow-fill-seal (BFS) vials per minute, the machine ensures hermetic packages even at high speed by featuring long-dwell cross-sealing technology. Primary packaging units, delivered as BFS cards, are gently fed into the Sigpack HCUL with the aid of a Sigpack LDF Delta robot or other intelligent loading solutions. Before being packaged in the flow wrapper, the vials are separated by the feeding system’s innovative separation unit.

Hermetic seal integrity thanks to long sealing time
Without compromising packaging integrity, the Sigpack HCUL long-dwell sealing system features a cross-sealing unit that allows the sealing jaws to close more gently and in a more controlled manner than other flow wrappers currently available – even at high speeds. This long-dwell sealing ensures longer sealing times to produce hermetic packages, which facilitates optimum product protection. The balcony design of the cross-sealing unit with individually mounted heating elements allows for easy access and fast changeover. Depending on application requirements, the station has the flexibility to be equipped with either ultrasonic or heat sealing technology. Also available are hybrid machines that use ultrasonic sealing technology on the longitudinal sealing unit and heat sealing on the cross seam. Because thermo-sensitive products can be damaged when exposed to heat, usually occurring when transported over the longitudinal sealing unit, this hybrid configuration provides a high-speed and extremely product-friendly solution for these products.

In process control ensures product safety
To realize the production of high-value products, the Sigpack HCUL is equipped with a comprehensive control system. Among other parameters, the system monitors the alignment of the products as well as the information printed on the packaging, such as the barcode. By making sure that packages which do not meet the specifications are automatically rejected, only hermetically sealed packages leave the machine. Jörg Kleiner, pharmaceutical and medical sales manager for Bosch Packaging Systems AG, a company of Bosch Packaging Technology, says, "Authorities such as the FDA increasingly demand that vials be packed separately and not as vial cards, also known as "unit dose packaging". Not only do pharmaceutical manufacturers need to meet these requirements, but at the same time maintain high productivity."

New MAP system improves product safety and extended shelf life
The flexible Sigpack HCUL is expandable to accommodate modified atmosphere packaging (MAP). Thanks to its modular construction, it can be modified for functions such as the innovative Real Time (RT) MAP system. Compared to conventional MAP systems, where the gas is inserted by a lance, the gas supply for the RT-MAP and the sensor for measuring residual oxygen content are integrated in the longitudinal sealing unit. As a result, this provides real-time measurement of residual oxygen content in the package, rejecting those that have excessive residual oxygen. The amount of gas supplied or extracted is precisely controlled so that only the necessary amount is released. The RT MAP system benefits manufacturers with improved measuring accuracy, as well as savings on production costs.

The Sigpack HCUL offers pharmaceutical manufacturers substantial advantages in the growing market for BFS pharmaceutical dosage forms, including a product-friendly and flexible feeding system, an innovative separation unit, and a product-friendly ultrasonic longitudinal sealing unit. The machine will be displayed as part of the BFS Seamless System, featuring a streamlined design for maximized overall equipment effectiveness (OEE). The speed of all line components is balanced to eliminate bottlenecks, minimize downtime and optimize product flow.