The document provides information about pharmaceutical packaging processes and machinery. It discusses tube filling, cartoning, bundling/wrapping, and other packaging processes used in the pharmaceutical industry. Tube filling machines use pneumatic components like cylinders and solenoid valves to automatically fill tubes with creams, gels, or liquids. Cartoning machines similarly use pneumatics to transfer filled products into cartons. Bundling machines wrap groups of cartons in film using cylinders for cutting, heating, and collating. Pneumatic components are critical for automating pharmaceutical packaging operations at high speeds.

1. What is packaging?
Packaging is the science, art, and technology of enclosing or protecting
products for distribution, storage, sale, and use.
OR
Packaging is the process of design, evaluation, and production of
packages.
OR
Packaging can be described as a coordinated system of preparing
goods for transport, warehousing, logistics, sale, and end use.
Packaging contains, protects, preserves, transports, informs,
and sells.
Each industry has its own packaging systems which required different
types of needs & machines.
On the packaging machinery side, while a wide range is
manufactured in India, the industry also imports machinery,
especially at the high end.
Pharmaceutical packaging industry encompasses all activities including
package testing and validation, package designing, development, package
prototyping and marketing of pharmaceutical products. The pharmaceutical
packaging industry primarily deals with packaging, handling, distributing and
storing of pharmaceutical products.
Some of the Pharmaceutical Packaging categories are:
Category Proces
Cream/ointment/gel in tube packaging Tube filling process
Powder in small jars /boxes packaging Powder filling process
Liquid in bottle packaging Liquid filling process
Tablet/capsule in aluminum pack or Tablet packing process
blister packaging
PACKAGING INDUSTRY
Pharmaceutical Packaging Industry

2. Example of Tube packing line
Product Product tank
1) Tube filling
Machine
2) Cartoning
Machine
3) Bundling /
Wrapping
Machine
4) Casepacker
Machine
Product Transfer Product
comes from the tank to
Hopper of the machine
through pipes.
Tube loading
unit
Packed boxes
comes at the outlet

3. Corrosion Hygienic High Electrostatic Standard
Resistant Design Frequency Removal Component
Filling Yes Yes Yes Yes Yes _ Yes
Bundling / wrapping Yes Yes _ Yes Yes Yes Yes
Casepacker _ _ _ Yes Yes _ Yes
Tube filling process is commonly used in the pharmaceutical & cosmetic industry.
It is a process of filling the product like ointment, cream or gel in laminate /plastic
tubes or in aluminum tubes.
As in pharmaceutical field mostly the product should be packed in clean room &
& minimum wastage of the product done while packing should be kept in the mind.
This is not possible manually by any person so tube filling machines are used.
Features of Tube Filling Machine:
Long Life
Yes Yes _Cartoning _ _ _
Process Heat Resistant
Tube filing process
Yes
No tube - No fill device which makes sure that filling does not take
place if tube is not present at the filling station.

4. At the orientation station, when the tube is lifted, its presence is
checked by a sensor and this signal is relayed to the filling station.
Hence if a tube is not there, the dosing action does not take place
and hence there is no fill.
If the tube is not ejected out by the ejector, the machine stops in
order to avoid damages.
In case of any jamming on the indexing system, to avoid
breakages, the load is sensed by the variable drive through the
PLC & the machine stops automatically.
Blow off device and tail cutting arrangements to avoid the paste /
Over load clutch to protect the indexer and all the related shafts
rods etc.
Solid state no tubes no fill device mechanism.
Tube holders are of spring loaded type to take care of any tube
diameter variation.
Over load clutch to protect the indexer and all the related shafts
rods etc.
Audiovisual Alarm Annunciation System for any abnormal
conditions of the machine.
Comprehensive control panel with all protection features.

5. Sections in Tube Filling Machines
1) Tube loading unit:
The empty tubes are first loaded in the cassette, which then travels through
the guides to be held in the feeder by vacuum.
The tube is then fed into the tube holder by the feeder
The tube holders are fitted on the circular turret which intermittently takes the tube
to all the stations.
Pneumatic Application: In this unit vacuum is needed to transfer the empty tubes from cassette
to tube holders mostly companies give separate small vacuum pump only
for this purpose we can suggest them our vacuum equipments
Also cylinders are used in high speed machines for loading the tubes.
2) Centering & Orientation unit:
The tube then passes through the centering station which presses the tube from
top and lodges it into the tube holder
It then travels to the orientation station for positioning the ‘I’ mark.
Here the tube is lifted and revolved. The moment the ‘I’ mark comes in front of the
scanner, the tube stops revolving and comes down.
Pneumatic Application: These two units also consist of cylinders which are mostly used in
high speed machines.

6. 3) Filling unit:
It is then carried to the filling station where the dosing action of the piston in the
cylinder forces out the required volume of material through the hose
pipe onto the suck back device and then from the nozzle into the tube.
Pneumatic Application : In filling units both cylinders & solenoid valves are used
the nos. of these are depend on the filling nozzles, maximum six nozzles machines
are present in the market right now. Also in many machines there is flushing
or cleaning unit before filling the product in tube, it is used mostly to clean the tube.
4) Crimping & ejection unit (For aluminum tubes):
Actuator used for filling process

7. The tube then travels through the individual pressing, crimping and coding stations
after which it is ejected out at the ejecting station.
Pneumatic Application:Each unit i.e.crimping, pressing & coding cylinders are used.
5) Hot Air blowing station (For lami/plastic tubes):
In case of lami/plastic tubes, after the filling station, the tube travels to the hot
air blowing station where hot air is blown onto the inside of the end of the
tube by a nozzle having holes on its periphery.
The tube then goes to the sealing station where the tube is pressed and sealed.
It then travels to the dual coding & trimming station where the tube is
first coded with metal stereos on the seal and the irregular shape at the tube
end is trimmed by a set of blades. It is then ejected out at the next station.
Pneumatic Application:Same as above for coding and trimming cylinders are used.
Important note: The machine which is fully automatic servo motor based & high
speed consist of minimum 8-10 cylinders also same no. of solenoid valves are used.
The machines which is low speed or semi automatic or induction motors based
consist of minimum 3-5 cylinders & solenoid valves.
Also fully automatic machines are 30% pneumatic equipment based consist of
tubing, fittings, pressure regulator, pressure gauges and pressure switch mostly.
Tube loading unit
Hopper

8. Tube filling machine
Tubing & fitting are also
used in every machine.
In small or semi -
automatic machine also
cylinders are used.
Tube loading unit
Filling Nozzles
Tube conveyor
HMI Touch screen

11. Cartoning process is very common in all industries, mostly companies
packed their product in cartons.
In the pharmaceutical sector there is a huge need for a cartoning machine
that minimizes to the least human contact with the product and at the same
attain a maximum speed needed, in cartons per minute.
system for the cartons from the magazine.
Also, its link up with the various blister packing machines completely
automates the packaging process for the drug which was not possible
so far with high outputs.
An extra-long powered conveyor to stack cartons which brings it to the magazine
Easily accessible drives that are isolated from the product path
Position indicators that enable quick tool-less changeover and can be replicated by
even semi-skilled personnel
Automatic Leaflet folding & feeding
Rotary pre-folded leaflet pick-up
Leaflet pre-insertion (for delicate products)
Printing device for flap embossing / debossing
Tuck-in / Hot-melt carton closures
Ink jet / laser jet coding unit
Centralized lubrication system
Bar-code security system
There are many types of cartoning machine some packed big product in a carton
& some packed very small product of minimum 3gms also.
Cartoning process
Features of cartoning machine
time gives high output for its large volume products.
It is a continuous motion, fully automatic, horizontal cartoning machine which can
This high speed is achieved by a specially designed Rotary pick-up
HMI
Push Rod assembley
Product conveyor

12. Pneumatic Application
In tube transfer unit where tube automatically transfers from tube filling machine
to cartoning machine there also a cylinder is used.
In rotary unit solenoid valves are used to control the on/off application of vacuum.
High Vacuum is needed to pick the carton & open the fold in high speed for which
only small vacuum pump is used.
In push rod assembly also small compact cylinder is used for the movements of the
Cartoning Machines

13. push rods
In servo based machines carton guard can be up & down automatically by
using cylinders on both sides.
For carton magazine unit also cylinder is used.
For empty carton rejection also at the outlet cylinder is used.
Besides this every machine consist of tubing & fitting also.
Carton pick up/rotary unit
Tubing, fitting & pneumatic equipment

14. There are many types of wrapping machine like simple wrapping or bundling machine,
shrink wrapping etc.
This machine is for over wrapping and sealing of rectangular cartons with cellophane
or BOPP film. The films kept in Rolls are cut to correct size, wrapped over
cartons and heat sealed. This machine is suitable for overwrapping rectangular shaped
cartons like tooth brush cartons, cassettes, blade dispensers and other rectangular
cartons used in pharmaceutical, cosmetic, food and similar industries.
Features Of Bundling machine:
Use of low-cost BOPP film or in some cases the cheaper HMHDPE
50% less power consumption than shrink-wrappers
All around protection from dirt and humidity
Product visibility lessens possibility of handling damage and petty pilfering.
Quick changeover with help of mechanical memory and position indicators
Use of Tear-tape and printed film.
Automatic transfer from upstream machine.
Bundling/wrapping/shrink wrapping process
Bundling machine
Product inlet
Product

15. Bundling process
Cylinders are used in cutting
section, side heating of the
bunch & also in collation unit.
Tubing & fitting

16. Features Of shrink wrapping machine :
Automatic Collation
Low film consumption - Cost saving in lower film consumption
Customized in feed and collection
Gives a transparent good looking packing.
Pneumatic Application
Cylinders are used in collation unit to make bunch & forwarding it to next unit.
For cutting of film by blade also cylinder are used.
For side heating & pressing the film cylinders are used behind heaters.
Beside this solenoid valves, tubing & fitting are used.

17. Series AFF can be mounted on the main air - line piping to remove t
oil, water & foreign particles coming in the compressed air - line from
It extends the life of the precision filters & enhances the life of other
Removes water from compressed air
Water droplet removal up to 99%.
No electricity required.
Space Saving
Should be installed at the peak pressure in the line & as f
compressor as possible for maximum efficiency.
Air-Line Equipments
Filters
Series AFF, Main Line Filter
Series AMG, Water Seperator

18. the impurities like
m the compressor.
r pneumatic
far from the

19. AF10 AR10 AL10
AF20 AR20 AL20
AF30 AR25 AL30
AF30 AR30 AL30
AF40 AR40 AL40
AF40-06 AR40-06 AL40-06
AF50 AR50 AL50
AF60 AR50 AL60
AF18 AR60 AL60
Residual pressure Release residual pre
relief 3 port valve
⅛,¼, ⅜ , ½, 3/ 4, 1
Cross Interface M5 x 0.8
Allows piping in all
⅛,¼, ⅜ , ½
Pressure switch ---- Compact Switch
Check Valve ⅛,¼, ⅜ Prevents back flow
Pressure Switch with ⅛,¼, ⅜ , ½, 3/ 4 Compact switch & p
Piping Adapter integrated into one
T- Interface M5 x 0.8
Re - directs the air f
⅛,¼, ⅜ , ½,
⅛,¼, ⅜ , ½, 3/ 4, 1 component without re
ATTACHMENTS
Photograph Port Size Func
Piping adapter M5 x 0.8 Allows installation or
AC55 6000 1
AC60 7000 1
AC40-06 4500 3/4
AC50 5000 3/4 , 1
AC30 2000 ¼ , ⅜
AC40 4000 ¼ , ⅜ , ½
AC20 500 ⅛ , ¼
AC25 1500 ¼ , ⅜
Model Applicable Series Flow Rate Port Size
AC10 90 M5 x 0.8
Bowl Material Polycar
Recommended Lubricant Class 1 turbine
Regulator construction Relievin
Filtration 5 μ
Ambient & Fluid Temperature "-5°C t
Set Pressure Range (AC 10 to 20) 0.05 MPa (AC
FRL
AC series
SPECIFICATIONS
Proof Pressure 1.5 M
Max. Operating Pressure 1.0 M

21. essure in lines.
four directions.
from lubricator
iping adapter
piece.
low
emoving the piping
ction
removal of the
¼
¼
¼
¼
⅛
¼
⅛
⅛
Pressure Gauge Port Size
1/16
rbonate
Oil (ISO VG32)
ng Type
μm
to 60°C
25 -60) 0.05 to 0.85 MPa
MPa
MPa

23. Series MB
Standard Air Cylinder
Bore Sizes: Ø32, Ø40, Ø50, Ø63, Ø80, Ø100, Ø125
Features:
a Low friction with a special "fig. 8" seal.
b High Kinetic Energy absorption
c Compact & Light weight
d Hexagonal wench for easy & fine adjustment of
cushion valves.
Series MBB
End Lock type/ Air Cylinder
Bore Sizes: Ø32, Ø40, Ø50, Ø63, Ø80, Ø100
Features:
a Locking Option on either sides / both side of the cylinder.
b Manual Release of the locks also possible
c All standard options for mountings are same as MB
Series MB1
Standard Air Cylinder with Square Tube
Bore Sizes: Ø32, Ø40, Ø50, Ø63, Ø80, Ø100
Features:
a Space saving auto switch mounting
b Better Asthetics, as tie rods are covered by square tube
c Easy Cushion Valve adjustment
d Special "Figure 8 Seal" for low friction.
e High Kinetic energy absorption.
Actuators
Standard cylinder

25. Tubings & Fittings
Fittings

26. Tubings

27. Solenoid Valves