Unpacking a complete tablet packing line
A journey through the process
At Rychiger, we pride ourselves on our ability to not only deliver cutting edge technologies from our portfolio, but also to integrate technologies from specialist suppliers, and to provide a professional project management to deliver a complete filling and packaging line.
In this recent example of a tablet counting line, we integrated machines from multiple suppliers to provide a seamless process for tablet packing for our customer based in Switzerland.
Join us on this journey
The user requirement for this application was to deliver a comprehensive production line that includes bottle feeding, air rinsing, tablet counting, nitrogen flushing, induction sealing, capping, labeling, cartoning, case packing and palletizing. And of course the line needed to ensure that all equipment met regulatory cGMP requirements and 21 CFR Part 11, to ensure the safety and efficacy of the products.
With six formats, the specified output was 70 bottles per minute with a maximum count of 120 tablets. The line needed to incorporate camera inspection at various process steps and connect to a supervisory system via OPC UA.
Our concept engineers came up with the perfect solution.
Bottle feeding
At the start of the line, bottles are loaded onto a Bi-flow belt by the operator. The bi-flow belt, also known as a bi-directional accumulation table, consists of two conveyor belts that move in opposite directions. This unique setup allows the system to create a buffer zone where bottles can accumulate temporarily providing 30 minutes of autonomy for the operators.
Bottles are recirculated on the table until the downstream equipment is ready to receive them. This is controlled by sensors and a recirculation gate. Once the downstream equipment is ready, the bi-flow belt feeds the accumulated bottles into the production line, ensuring a continuous and smooth operation.
Air rinsing
The Rychiger solution
The next step in the process involves cleaning the bottles using a combination of compressed air and vacuum. Bottles enter the scrolled in-feed and are accurately positioned under the air rinsing unit. This non-inverting bottle air rinsing unit uses a timing screw to transport upright bottles through the cleaning process.
High-pressure air nozzles, utilizing ionized air, dislodge particles from the bottle interiors which are then extracted by a vacuum system. This method is efficient, cost-effective, versatile, and enhances product quality by ensuring bottles are clean before filling, making it valuable addition to the line.
Tablet counting
A conveyor connects the cleaned bottles to the Cremer CFS tablet counter. This versatile and efficient machine features a modular design that can accommodate up to four counting modules, though in this case the machine was equipped with two.
Each module can handle up to 50 bottles per minute providing a maximum output of 200 bottles per minute when using four modules. The CFS ensures 100% counting accuracy, reducing errors and waste. Its compact footprint allowed it to fit seamlessly into our line layout. The machine proved itself to be user-friendly, thanks to servo-driven components and a fully transparent enclosure.
Nitrogen, induction seal and capping
The flexible Z-201
Our flexible Z-201 platform is the next machine in the process. Utilizing a walking beam to transport two bottles per cycle, the unit efficiently handles the required 70 bottles per minute. The process begins with nitrogen injection to eliminate oxygen from the container. Next, a foil seal is precisely placed on top of the bottles before moving to the induction sealing units. A camera then checks the position of the seal before the Pilferproof metal screw caps are placed onto the bottle. The final step is performed by the rotary crimp capping units. The machine is equipped with an eject mechanism and sensors at all processing steps.
The Z-201 is engineered for optimal uptime, allows for a swift and efficient format change without the need for tools. It includes standard features such as user access, batch protocols, a compliant audit trail, and OPC UA connectivity. The implementation of recipe control ensures an error-free process.
Labelling
Filled and closed bottles transfer via rotary table to the labelling machine.
The VRM series labeling machine from b+b automation applies labels quickly and precisely. The machine features a 3-roller turning station and has a modular design, allowing for easy expansion and adaptation to different products without tools.
The machine incorporates a thermal transfer label printing system and vision system to ensure quality and correct label placement. An eject mechanism removes incorrectly labeled or defective products from the machine, ensuring only correctly labeled items proceed to the next stage.
Vertical Cartoning machine
The vertical cartoning machine is a reliable addition to the tablet packaging line. It features a linear drive system and fully automatic format adjustment, efficiently handling product and leaflet feeding.
Bottles are transferred from a turntable to a flat feed conveyor, separated by a feed screw, and positioned for a servo-controlled pick & place unit, which inserts products and their leaflets into cartons. Leaflets are folded by a GUK folding machine, checked for barcode accuracy, and only those with verified barcodes proceed to the insertion station.
The machine performs erecting of cartons, folding and printing on the bottom flap, barcode checking, OCR/OCV inspection, closing cartons, filling them, checking for product and leaflet presence, folding the top flaps, and closing the top. Cartons with errors are ejected, and the rest are transferred to a conveyor belt for further processing
The final step
The final step in the process involves an automatic vertical case packing and palletizing machine. Incoming cartons are taken from a flat feed belt and fed into the case packer. The cartons are transferred from the upstream linear cartoner to a flat feed belt, grouped in the shipping carton according to a set pattern, and inserted as a group using a pick & place unit.
The machine's workstations include erecting the case, folding and sealing the lower flaps with hot glue, filling the carton with products, checking product presence, folding and sealing the upper flaps with hot glue, and discharging the carton.
After discharge, the cartons are transferred on a flat conveyor belt, undergo weight control, have labels applied and checked, and are fed to the palletizing robot's pick-up station. The robot uses a vacuum gripper head to place cartons on a configurable pallet. It processes pallets of 800x1200 mm size, achieving a stacking height of 1,500 mm.
Why choose Rychiger?
Choosing a tablet counting line from Rychiger ensures your company benefits from exceptional attention to detail and professional project management. Renowned for our meticulous approach, we optimize every aspect of the process for accuracy and efficiency. Our commitment to quality is evident in the comprehensive documentation provided, meeting all regulatory requirements.
Partnering with us guarantees your production line will be managed with the highest standards of professionalism, ensuring reliable long-term performance. We embody Swiss quality and reliability, offering excellent service backup to support your operations. Our advanced technology ensures precision and innovation in every step, making Rychiger the ideal choice for your next tablet counting line.
Contact James to schedule a meeting for your tablet counting line!