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Pkg 432 Bayer Project Presentation
- 1. Bayer Low Dose 81mg 120ct Packaging Line David Brennan PKG 432, Fall 2008 A33857323 http://www.mybayerjob.com/images/Bayer_Logo_neu2.jpg
Editor's Notes
- Aspirin is commonly referred to as Acetylsalicylic Acid, a white crystalline and odorless substance. This is the active ingredient of aspirin. The other raw materials used in aspirin, corn starch, water and a lubricant, are strictly used to alter the physical properties of the substance in order to manufacture them in tablet form at mass quantities. Corn starch and water acts as a binding agent to hold the acetylsalicylic acid together in a tablet form. These two ingredients also act as a filler to increase the bulk of the ingredients to produce an adequate size tablet. There are various possible lubricants that can be used so that the tablets won’t stick together, including hydrogenated vegetable oil or stearic acid to name a couple. Once in tablet form, it is important that they are not altered physically and chemically in any way throughout the packaging, storing and shipping process. In this hardened state, the tablets are susceptible to a number of physical damages such as breaks, chips and scrapes that may not seem serious, but may completely change the dosage and communication of an individual pill and possibly affect these attributes in other tablets in the bottle as well. Many tablets are branded in order to identify exactly what kind of medication it is and what company manufactured it. Certain codes are also used in order to identify exactly when and where that batch of aspirin was manufactured. If this brand is scraped off somehow, it can create a liability issue for the company if someone is harmed by the medication due to lack of identification and create difficulties when a specific tablet must be pinpointed for troubleshooting issues. Any of these damages could also affect tablets that have coatings applied; this coating is applied so it is easier to swallow. If this coating is damaged it may take away that ease and create not only a liability for the danger it may cause but also because it creates an issue of false advertising. For these reasons, it is important that the aspirin tablets are put through quality control to insure the tablets are the correct hardness and fragility to guarantee they will not be damaged under normal conditions throughout the packaging lifespan. Aspirin has a melting point of 135 degrees Celsius, so it is important that the pills never reach a temperature equal to or above this. It is also important to keep the tablets in dry conditions. Aspirin tablets are meant to dissolve in the human body after they are swallowed, but that means they are water soluble, hydrolyze in moist air and decompose in hot water. The solubility of aspirin in water is 1g/100g at 37 degrees Celsius. As a result, aspirin is most stable in dry air. But no matter how dry the air and perfect the conditions are, it will inevitably deteriorate over time and lose its effectiveness of use. This deterioration only allows companies to guarantee the efficiency and safety of aspirin for a certain amount of time. It is an over the counter drug that is used my millions of different people in different locations around the globe. So it is important to keep in mind the magnitude of this market and how this medication can affect a number different people for a broad array of reasons. Every side effect and warning must be communicated clearly to the customer’s that purchase the aspirin. The particular aspirin used for this project is a low dose, 81 mg aspirin made by Bayer. It is specifically made for babies and contains 120 enteric coated tablets. It is important that the product meets all these requirements before and throughout manufacturing to consumption.
- The primary packaging system for a bottle of aspirin is made up of 6 components. These components include the bottle, a desiccant, cotton, foil induction seal, cap, and a label. HDPE Bottle Bottle is a 75 cc extrusion blow molded HDPE bottle weighing 13 g supplied by Drug, Plastic and Glass Co. Protects people by preventing unwanted substances from contacting the tablets, when used concurrently with cap. Provides a barrier from the biosphere from such things as light and moisture, when used concurrently with cap. Protects from physical damage by absorbing shock, providing a barrier to contain the aspirin tablets and prevent puncture. Reduces the threat of tablets to break or chip. Smoothness of bottle eliminates chance of package to scrape the pill. Desiccant It is a ½ gram 2-in-1 can made of injection molded polypropylene and supplied by SUD-CHEMIE. Protects people by keeping the aspirin fresh. Silica gel in canister absorbs any moisture in bottle and prevents the tablets from sticking together and activated carbon to absorb gases and odors. Sized appropriately in order to insert and remove from bottle with ease. Size, shape and color far different from that of the tablets and help to prevent accidental consumption. Cotton Supplied by Allenberg Cotton Co. and delivered in spools. Provides protection for the tablets by softening and decreasing the head space in the bottle to prevent breaking. Can serve as a moisture barrier. Foil induction seal Made of aluminum and supplied by Drug, Plastic and Glass Co. as part of the cap. Provides an air tight seal by being induction sealed over the bottle opening. Compromises utility for some people because it can be difficult to completely remove. Cap Made up of a two piece injection molded polypropylene inner cap and outer cap supplied by Drug, Plastic and Glass Co. Size matches the 38-400 finish of bottle. Protects people by utilizing a standard child resistant push and turn feature that satisfies utility by making it is easy for adults to open. Contains all the contents inside and provides a barrier from outside contaminants. Communicates with people by providing directions on how to remove the cap using words and symbols. Label Made by CCL label, it’s a 4.75” x 1” paper label with and over varnish to prevent scuffing. The label itself is about 1 mil thick. It is applied using a pressure sensitive silicone adhesive. The purpose is to provide communication about product to people and machines. Active Ingredients, Uses, Directions, Title/Brand Name, Manufacturing Coding, Warnings, Contact Information, Expiration dates, and Lot and Date coding Acts as an advertisement by printing the brand name and logo. The primary packaging system for a bottle of aspirin is made up of 6 components. These components include the bottle, a desiccant, cotton, foil induction seal, cap, and a label. HDPE Bottle Bottle is a 75 cc extrusion blow molded HDPE bottle weighing 13 g supplied by Drug, Plastic and Glass Co. Protects people by preventing unwanted substances from contacting the tablets, when used concurrently with cap. Provides a barrier from the biosphere from such things as light and moisture, when used concurrently with cap. Protects from physical damage by absorbing shock, providing a barrier to contain the aspirin tablets and prevent puncture. Reduces the threat of tablets to break or chip. Smoothness of bottle eliminates chance of package to scrape the pill. Desiccant It is a ½ gram 2-in-1 can made of injection molded polypropylene and supplied by SUD-CHEMIE. Protects people by keeping the aspirin fresh. Silica gel in canister absorbs any moisture in bottle and prevents the tablets from sticking together and activated carbon to absorb gases and odors. Sized appropriately in order to insert and remove from bottle with ease. Size, shape and color far different from that of the tablets and help to prevent accidental consumption. Cotton Supplied by Allenberg Cotton Co. and delivered in spools. Provides protection for the tablets by softening and decreasing the head space in the bottle to prevent breaking. Can serve as a moisture barrier. Foil induction seal Made of aluminum and supplied by Drug, Plastic and Glass Co. as part of the cap. Provides an air tight seal by being induction sealed over the bottle opening. Compromises utility for some people because it can be difficult to completely remove. Cap Made up of a two piece injection molded polypropylene inner cap and outer cap supplied by Drug, Plastic and Glass Co. Size matches the 38-400 finish of bottle. Protects people by utilizing a standard child resistant push and turn feature that satisfies utility by making it is easy for adults to open. Contains all the contents inside and provides a barrier from outside contaminants. Communicates with people by providing directions on how to remove the cap using words and symbols. Label Made by CCL label, it’s a 4.75” x 1” paper label with and over varnish to prevent scuffing. The label itself is about 1 mil thick. It is applied using a pressure sensitive silicone adhesive. The purpose is to provide communication about product to people and machines. Active Ingredients, Uses, Directions, Title/Brand Name, Manufacturing Coding, Warnings, Contact Information, Expiration dates, and Lot and Date coding Acts as an advertisement by printing the brand name and logo. The secondary packaging system is made up a paperboard carton and a pamphlet. Carton Made by Packaging Graphics using 6 colors. Blank design and dimensions attached (created with ArtiosCAD). Sealed using Hot Melt Adhesive GIA1048 from Glue Machinery Corporation As described in its name, this hot melt adhesive must heated and melted in order for it to be applied and hardens once it is cooled. Provides protection for the primary package as well as additional protection for the aspirin. Communicates additional information to people and machines by printing many of the same items that were printed on the label and sometimes more. Provides physical communication through the printing of barcodes in order to quickly track it throughout many phases of the supply chain. From the packaging line to the sale of the aspirin in stores. Acts as an advertisement through its colorful graphics and branding placement. Pamphlet Made of bleached virgin paper and supplied by CCL with dimensions of 5.3125” x 4.1875”. Allows the Aspirin packaging system to communicate additional information that is similar to that of the label and carton. The tertiary packaging consists of a shipping case, a pallet and stretch wrap. Shipping case A standard corrugated C-flute 42-26-42 (2, 2, 4) Regular Slotted Container (RSC) made by Smurfit Stone. Sealed using Hot Melt Adhesive GIA1051 from Glue Machinery Corporation. As described in its name, this hot melt adhesive must heated and melted in order for it to be applied and hardens once it is cooled. Provides protection from damage for product as well as the primary and secondary packaging. Printing on case provides communication to people and machines by branding, coding, etc. Pallet Made by CHEP, standard Mark 55 48”x40”. Made of kiln-dried Southern Yellow Pine and nails. Provides a flat and sturdy platform to ship aspirin in bulk. Designed specifically to be used with a forklift for transporting and loading. Stretch wrap It is a machine stretch film made of linear low density polyethylene Supplied by Stretch Wrap Supply. Are supplied by rolls with dimensions of 20” wide, 8000 feet long and 55 ga. Costs $44.18 when purchasing over 15 rolls. Stabilizes loads by tightly holding all individual shipping cases together as one load.
- Conveyor System The conveyor system used is manufactured by NJM/CLI Packaging Systems International. The conveyor system effectively links all of the machines together, transporting the product/package to the consecutive machine. The conveyor is constructed from a 304 stainless steel and is designed according to cGMP regulations. The conveyor system utilizes a raised bed conveyor with an adjustable guide rail, as well as an adjustable speed control.
- Bottle Orienter The Pharma-Line M300 by Pace Packaging Corporation is the bottle unscrambler we choose for our line. This machine is well suited for pharmaceutical production lines, can run at speeds up to 250 bottles per minute, and works like the following. “The elevator feeds the bottles from the hopper into the rotating disk where they are spun by centrifugal force into neckleading and baseleading positions for introduction to the infeed tooling. The pre sorter displaces misaligned bottles back to the rotating disk. The infeed belts capture neckleading and baseleading bottles for transfer to the hook mechanism. Baseleading bottles pass under the hook while neckleading bottles are hooked into a baseleading position for inversion over the air rinse station. Inverted bottles pass over the ionized air rinse station, which consists of an ionized air knife with concurrent surrounding vacuum. Bottles are placed in upright position and stabilized for exit to the conveyor and are ready for the next step in the filling process.” ( www.pacepkg.com ) The Pharma-Line M300 is made of steel components so it is very easy to clean and has a five minute tool-less changeover.
- Filler The tablet filler used is a SureFill 300 Slat Filler with a SureCount inspection system manufactured by Service Industries. The tablets are contained in a built in hopper, and from there are conveyed to the slat filler. The tablets are then placed into industry standard slats, which accept a specific amount of tablets for the desired application. For our product the filler utilizes 16 slats for the corresponding 120 count amount of tablets. The SureCount inspection system utilizes an infrared detection system to verify that each slat contains tablets, therefore eliminating incorrect tablet counts. Once the slats are filled the tablets are then released and placed into respective bottles. This machine is capable of running at speeds of 300 bottles per minute.
- Checkweigher This machine is made by Thermo Scientific and the model is the Ramsey GP-Pharma which utilizes a Ramsey AC9000-Plus controller. The Ramsey GP-Pharma is suited for small packages and offers high accuracy of +/- 0.2g in dry environments, up to 350 containers per minute. The checkweigher uses low-friction aluminum conveyors and dynamically-balanced weigh-table rollers which are powered by 40-watt DC motors. The checkweighing machine can also be integrated with an optional DSP IP Plus metal detector. The Checkweigher is controlled by the AC9000-Plus unit. The controller has an interactive menu structure and color display as well as a 32-bit microprocessor. The unit is capable of being connected to a PC to give graphical statistic displays, diagnostics, network communications, and servo feedback.
- Labeler The labeler is made by Krones and the model is Autocol. This labeler utilizes rotary machines; two star wheels and a rotary machine. The labeler is capable of automatically applying a verity of pressure sensitive label materials of all shapes, sizes, and substrate types. The rotary machine guarantees precise guidance of containers to the label applicator for consistent and accurate application. This machine is capable of applying labels to 16 - 800 containers per minute depending on container size. The Autocol is a continuous-motion machine that automatically adjusts to the incoming and outgoing containers. The machine utilizes an in-feed worm to space out containers to be received by the star wheel, which feeds the rotary machine. Upon the rotary machine the containers are placed between container plates and centering bells which are driven by a computer-controlled servo-drive. The containers are then rotated during the introduction of the label from the peal plate and then are wiped by a brush or squeegee to insure adherence. The containers are then diverted back to the packaging line conveyor via the second star wheel. The APS 3 label applicator can be adjusted using a digitally adjustable starting position and is capable of inspecting the labels and carrier web with ultrasound for rips and tears. The Bayer aspirin label is a semi-wrap-around paper label that almost completely goes around the entire bottle and will require the bottle to be rotated quickly upon introduction to the label and the wiping brushes.
- Ink Jet This printing system is supplied by Inc. Jet which uses a sophisticated HP based printing process. The hardware is made up of a print engine that houses three cartridge slots for a total print width of 1.5” with print densities up to 600dpi for sharp images and text. The printing engine can be connected to a PC via Ethernet interface and used with a Windows based graphical user interface program. The program allows the user to input the desired data to be printed on the bottle’s label; in the case of the Bayer bottle, the lot and date code printed on the label. The thermal inkjet technology is a non-impact printing technique that produces high quality results without excess costs, lost time, or wasted ink. The ink cartridges are provided by Inc. Jet, have a 45ml capacity, and come in a variety of colors and can be used on a variety of different substrates.
- Desiccant canister feeder This desiccant canister feeder, model CDFI is made by the Omega Design Corporation and has an adjustable freestanding mobile frame that can be easily moved over existing conveyors. It also has a stainless steel frame and contact parts, a rotary disc sorter with five gallon floor level hopper with elevator, a desiccant verification system with a beacon to alert fill status, adjustable indexing stops for quick changeover, a programmable logic controller, and a selector switch for single, double, and triple drops at 120, 75, and 55 containers per minute. The moisture and odor adsorbing 0.5g 2-in-1 can that uses is a combination of silica gel and activated carbon from Süd-Chemie and will be used with this machine using a single drop at 120 cpm.
- Cotton Feeder The Cotton filler we choose for our line is the Cotton Star by Capmatic. It is used with natural cotton supplied as a continuous coil. The Cotton Star separates the coil into each plug by pulling the cotton coil apart between two pairs of servo motor driven pinch rollers, so no sharp cutting blades are used. The plug is formed into an inverted U-shape and inserted into a bottle by an air cylinder. This machine includes bottle detection, bottle back-up, and “no cotton” sensors. The Cotton Star can run up to 120 bottles per minute and can produce cotton lengths from 2” to 9”.
- Capper The capper used is a beltorque BT-IC automatic in-line capper manufactured by NJM/CLI Packaging Systems International. The capper contains an integrated cap elevator and cap chute, where the caps are oriented and carried up to the chute which supplies the capping mechanism with the caps. Then the caps are installed at two different stations; the first station applies the cap and the second station tightens and torques the cap to the desired torque; there is also an available cap inspection with rejection system. This machine is capable of running at speeds of 200 bottles per minute.
- Induction Sealer The induction cap sealer is made by Enercon and the model is Super Seal. This sealer has a compact all-in-one power supply and sealing system using little floor space and no maintenance. Standard and custom sealing heads are available for every cap sealing requirement which speeds productivity and efficiency. This model comes standard with a microprocessor control and plug-in induction sealing heads. This unit is also air-cooled and water friendly, having a sealed electrical compartment to allow for line wash-downs.
- Vision system: The vision system used for this packaging line is made by Laetus where a compact controller is used in combination with an iCAM compact camera. The compact controller connects to a computer through a USB or Ethernet cable and has a Intel core due 2x1.66 Ghz processor built-in. Four camera units can be connected to the controller using FireWire IEE1394b. This system is capable of inspecting all standard 1 and 2 dimensional bar codes as well as bar code print quality. The system is also capable of optical character recognition in all print processes, normal/inverse print, horizontal/vertical orientation, and different fonts. An alignment check module is also standard that can inspect position of labels for angle, position and alignment. The system also has a pattern matching module that inspects for the presents of caps, bottles, labels, and logos using a good, not good evaluation. This Laetus vision system will be used in conjunction with a ARGUS 6012 Ejection Verification system that ejects and documents when a product is rejected. The Laetus vision system will be used in the Bayer package system to inspect both the primary and secondary packages. It will look at label placement, label content, bar codes, lot and date codes, printing quality, and presents of the cap, bottle, label, and carton.
- Accumulation Tables The accumulation tables used are manufactured by NJM/CLI Packaging Systems International. The purposes of the accumulation tables are to accumulate the product/package at points in the line that are a bottle-neck. For example, there is an accumulation table before the cartoner, as the cartoning process is more involved and takes longer than the previous processes to complete. The accumulation table used is a circular version, which is constructed of a 304 stainless steel with a variable-speed motor with reducer and DC control unit.
- Cartoner The cartoner is an automatic vertical cartooning machine from Marchesini and the model is MAV 50. This machine is specifically designed to handle pharmaceutical products by using delicate handling of the products and cartons. The cartoner is capable of embossing, ink-jet, and laser printing as well as pamphlet insertion which are placed in a U position around the product. This machine is also equipped with an automatic reject of incomplete cartons, is maintenance free, and offers very short change-over times. The MAV 50 uses a positive carton transport using grippers fitted on a belt that hold the erected cartons for product and pamphlet insertion. Cartons start out in a carton magazine that is then picked up and opened by suction cups, and then it is picked up by the grippers and embossed shortly after. Then the carton bottom is sealed by glue and then the bottle is inserted, shortly followed by the pamphlet insertion and sealing of the top. Before leaving the cartoning machine the cartons are inspected automatically for completeness and then it is either discarded or it continues on to the case packer.
- Case Packer This machine is a top loading case packer made by Serpa Packaging and the model is the P250. The case packer is all servo driven, has a compact footprint, uses hot melt glue or tape, offers fast and accurate changeovers, and is low maintenance. The machine starts out with a magazine filled with flat cases, which are taken out one at a time with vacuum grippers and erected. The bottom of the case is then sealed with hot melt glue before product is vertically loaded in the case via vacuum grippers. The P250 is equipped with a product funneling conveyor that allows for the 4x3x2 carton configuration within the case that is specified by the pallet pattern. Then the case is sealed at the top with more hot melt glue before it moves to the pallitizer. The P250 is capable of producing 20 cases per minute and allows for a 5 minute, no-tool changeovers.
- Case Labeler The case labeler for the line is the Model 400 Print & Apply Case Labeler with Zebra Printer by NJM/CLI Packaging Systems International. First, the lot specific information gets entered into the printer. After each label is printed, it is automatically peeled from the liner and held by a vacuum on an applicator pad. The pad is on a rotary swing arm. The rotary swing arm reaches across the conveyor and blows the label onto the front panel of the moving case. Then the arm rotates around the corner of the box to press the label down on the side of the case. This produces a corner wrap label which shows the lot specific information on two sides of the case. The Model 400 Case Labeler can run at speeds up to 50 cases per minute and has RFID tagging capabilities.
- Palletizer The palletizer used is a FL100 floor level palletizer manufactured by Columbia. The cases coming from the case packer are conveyed directly to the palletizer, which orients and places the cases in the correct pallet pattern. A pallet is put into place via an automatic pallet feeder, which the cases are placed onto in their respective pallet pattern. Once the final tier is placed onto the pallet, the loaded pallet is then conveyed onto the stretch wrapper. This machine is capable of running at speeds of 20 cases per minute.
- Stretch Wrapper The stretch wrapper is a Predator Platinum model manufactured by Highlight Industries. It has a round turntable with a diameter of 65” which can sufficiently support the standard GMA 48” x 40”pallets that this packaging line will be using and is capable of wrapping pallets loads that are up to 80” in height. It’s controlled simply with a control panel with a Programmable Logic Controller and touch screen. The turn table has a small outer wall on the outside that is about 2 feet long and 6 inches high that serves as the placement for the initial attachment for the stretch wrap. A swinging automated arm attaches the wrap to this small wall and then the turntable begins to spin. After the first full rotation, a small metal rod automatically swings out from the inner part of this wall and detaches the stretch wrap from the wall. The turn table continues to rotate the pallet load simultaneously with a mechanism that has the roll of stretch wrap attached that rises up to the height of the load and back down to the bottom and creates a double wrapping. This machine also has the capability to pre-stretch the stretch wrap as its being applied. When the load is completely wrapped, the automatic arm that applied the stretch wrap to the small wall cuts the wrap off of the load. The load is manually loaded onto the stretch wrapper turntable by a forklift operator and removed by this same forklift operator. It is also possible for this same operator to operate the stretch wrapper machine.
- The bottles get brought to the line in cases. The first line worker opens the cases of bottles and dumps them in the hopper of the bottle unscrambler. This is done approximately every twenty minutes as determined by the line speed and size of the hopper. The line worker keeps an eye on the bottle hopper and refills it when it gets low. The corrugated cases get broken down and set aside on a pallet to later be removed from the line and taken to the corrugated recycling. The tablets arrive to the line in drums. They get dumped in the tablet hopper at the beginning and approximately every two hours get refilled. The line worker watches the hopper to see how many tablets are left in the hopper, but because they are so small, restocking doesn’t need to happen that frequently. The same line worker that stocks the bottles also does the tablets. The desiccants are brought to the packaging line in drums. The first line worker initially dumps the desiccant in the hopper and then restocks as necessary during the production run. The restocking happens approximately every three hours since only one desiccant goes into each bottle. The cotton comes in coil rolls that are in cases. The first line worker opens up the case and takes out a cotton coil to place it in the cotton filler machine. This needs to be changed approximately every three hours since only one cotton piece goes into each bottle. The caps are packaged in cases just like the bottles. These cases are opened and the caps are dumped in to the capper hopper. The corrugated cases get broken down and set aside on the pallet with the other broken down corrugated. The elevator takes the caps from the hopper to the capper and ensures that all the caps are facing the correct way. The second line worker is responsible for restocking the capper hopper. The restocking is done approximately every hour since a lot of caps can fit in the hopper at one time. The labels arrive to the packaging line in cases that contain the label roll stock. The second line worker opens the cases, breaks them down, and places them on the broken down corrugated pallet. The label rolls get placed on the primary and backup label wheels to ensure that the machine never runs out of labels and has to stop production. The label rolls get replaced approximately every hour and a half based on how many labels each roll holds. The liner from the labels gets thrown in the waste basket. The second line worker is also responsible for stocking and restocking the cartons and inserts for the cartoner. The cartons are packaged flat in cases. The line worker opens each case and puts the flat cartons in the magazine in the cartoner machine. The cartons are replaced approximately every half-hour or as the line worker sees the magazine getting empty. The inserts are packaged in trays in cases. After the line worker opens up the case, each tray is taken out and inserted in the magazine in the cartoner machine. Then the cases from both the cartons and inserts get broken down and placed on the corrugated pallet. The inserts are re-stocked approximately every twenty minutes or as the line worker sees the magazine getting low. The corrugated cases arrive on the packaging line in bundles. The third line worker cuts the bands and places the cases in the case packer machine. The restocking occurs approximately every half-hour or sooner if the line worker sees the case supply diminishing. The bands get thrown away in the waste baskets on the line. The case labels come blank in rolls. The third line worker initially places the blank label roll on the case labeler wheel. The blank roll stock gets changed approximately every four hours, depending on how many labels are on each roll. So when the third line worker sees the roll is getting low during production, they will grab a new roll and get ready to change it. Stretch wrap comes to the line in big rolls. These rolls get placed on the palletizer by the third line worker. These rolls don’t need to be changed every day, as they’re only used when a pallet is complete. The stretch wrap rolls get replaced when the indicator on the machine says it’s getting low, and the third line worker can see that there’s only a little bit left.
- This packaging line will include three line workers. One worker will monitor and fill the bottle orienter, pill filler, desiccant feeder, and cotton feeder. Another worker will monitor and fill the capper, induction sealer, labeler, maintain the accumulation table, and cartoning machine. The last worker will monitor and fill the case packer, palletizer, and stretch wrapper as well as assist the fork truck driver with the delivery and export of inventory. The desiccant and cotton feeders will be the limiting machines because they have a max speed of 120 containers per minute. This makes the total output of the line at 5 cases per minute.
- All of the incoming shipments of supplies for the packaging line must be approved by quality prior to use. This includes both the product and all of the packaging components. Typically there is little QC work on incoming components, especially components coming from trusted, previously used suppliers. All of the components must meet the specifications agreed upon by the suppliers. Although, once there is an issue on the line with a faulty component, QC will check the component against the agreed upon specification to make sure there isn’t an issue with the quality of the component. Most of the machines on the line have built-in features to ensure the quality of the specific task performed by the machine. For example, the filler has an infrared detection system that determines how many tablets are going to be inserted into the bottle. There are also several QC checks on the line. The first QC location is after the first check weigher, where rejected bottles are removed from the line to be examined for their cause of rejection. The second QC location is after the induction sealer, where sealed/capped bottles undergo a leak detection test using a leak tester to determine the quality of the seal made by the induction sealer. There are also vision systems in place after the labeler and the cartoner which inspect the primary and secondary packages. The vision systems are specifically looking at label placement, label content, bar codes, lot and date codes, printing quality, and the presence of the cap, bottle, label, and carton. There typically isn’t any end of production QC checks, unless it is an initial line trial. During an initial line trial the product/package system is inspected at the very end of the packaging process to ensure both the quality of the product and the package.
- Case packer by: Serpa Packaging Solutions http://www.serpapkg.com/p250.html Filler by: Service Industries http://www.serviceindustries.biz/surefill%20300.html http:// www.serviceindustries.biz/surecount.html Capper by: NJM/CLI Packaging Systems International http:// www.njmcli.com/beltorqueAILC.html http:// www.njmcli.com/swfvideo/beltorqueAILCV.html Palletizer by: Columbia http:// www.palletizing.com/E_series_floor_level_palletizers.php # Accumulation table by: NJM/CLI Packaging Systems International http:// www.njmcli.com/accumtables.html Ink Jet by: Inc. Jet http:// www.incjet.com/Products.html Cotton feeder by: Capmatic http:// www.capmatic.com/cottonstar.html # Bottle Orienter by: Pace Packaging http:// www.pacepkg.com/Unscramblers.htm#Pharma -line Conveyor system by: NJM/CLI Packaging Systems International http:// www.njmcli.com/conveyor.html Case Labeler by: NJM/CLI Packaging Systems International http://www.njmcli.com/400.html Stretch Wrapper by: Highlight industries http:// www.highlightindustries.com/predator.html Aspirin References: http://chemicalland21.com/lifescience/phar/ACETYLSALICYLIC%20ACID.htm http://www.madehow.com/Volume-1/Aspirin.html http:// www.aspirin.com/faq_en.html Desiccant http://www.bbc.co.uk/dna/h2g2/A1029331 Child-resistance closures http://www.tpub.com/content/armymedical/MD0810/MD08100080.htm Label adhesive http://www.lgintl.com/LabelEducation/PSL/label-education-adhesives.htm Cotton supplier http:// www.allenberg.com / Quality Issues http://www.devicelink.com/pmpn/archive/06/10/005.html http:// www.manufacturingtalk.com/indexes/categorybrowseml.html
- This pallet pattern utilizes a column-interlocked configuration that allows for optimal stacking strength by keeping about 80%, compared to a strait column stack. The 4x3x2 carton configuration allows for easy channeling within the diversion track of the case packer and provides an optimal case size for pallet load stability. This particular pattern has a high cube and area efficiency that will equate to a higher score on the Wal-Mart scorecard.