Packaging Technology

Achema 2015 Residue-free cleaning: new exterior washing machine RAN 3080 from Bosch High-pressure cleaning process eliminates contamination and product residue

  • Exterior cleaning of up to 400 vials, ampoules or cartridges per minute
  • Specially developed transport gripper for comprehensive cleaning of container surface
  • Flexible washing stations enable usage of up to three media
Frankfurt/Main, Germany - At Achema 2015, Bosch Packaging Technology presents the new exterior washing machine RAN 3080 for vials, ampoules and cartridges. The machine removes product residue and other contamination from filled and closed glass containers via a newly developed, efficient high-pressure cleaning process. The transport system, which has also been developed by Bosch, grips the containers at the closure, ensuring an effective cleaning of virtually the entire container surface. "With the RAN 3080, we are consistently expanding our product portfolio for processing and filling of liquid dosage forms," explains Tobias Göttler, product manager at Bosch Packaging Technology. "By combining the new exterior washing machine with our numerous other solutions, we can design a flexible line concept."

Preventing product contamination
The safety of employees and patients comes first for pharmaceutical companies. Consequently, the exterior cleaning of containers after filling and closing plays an important role. "The new RAN 3080 enables the elimination of process-related contamination, which could harm recipients' and patients' health," Göttler says. "By combining the high-pressure process with an efficient transportation system, the new development allows for a residue-free cleaning of up to 400 containers per minute for the first time."

The machine consists of a rotary platform for cleaning and an identical rotary platform for drying. Following the infeed, the transportation system first grips the container by their closure caps. This enables cleaning of virtually the entire container surface, including the neck. The newly developed ring nozzles of the cleaning station, which for the first time operate with high pressure, subsequently wash the containers from top to bottom. Additional bottom nozzles provide for clean container bases. Pressurized air continuously flows across the closure caps. It stops moisture from getting to the closure rim and into the containers, thereby preventing product contamination.

Individual cleaning and thorough drying
The RAN 3080 features three individual washing stations, which enable the cleaning processes to be optimally adapted to different customer demands. Up to three different media can be used per cycle; apart from water, acids and alkaline solutions are applicable for heavy contamination. Drying also takes place at three stations with pressurized air from both ring and bottom nozzles, and ensures that no residual moisture sticks to the containers. Thanks to a strict separation of cleaning and drying area, the machine further prevents a re-contamination of the containers after washing. "Due to its residue-free cleaning and hygienic design, the RAN 3080 also complies with the high requirements for manufacturing highly potent pharmaceuticals, such as cytostatic drugs," Göttler underlines. The identical construction of the two rotary platforms further enables significant savings in spare parts inventory.

Depending on production requirements, the washing machine can be equipped with different containment devices: options range from containment housing for the protection against harmful and toxic substances to macrolon covers for non-toxic applications. An optional circulation system achieves significant savings by consistently re-using slightly contaminated cleaning media.

Bosch's technologies are on display at Achema in Frankfurt/Main, Germany, from June 15 to 19, hall 3.1, booth C71.

Tobias Goettler
phone: +49 7951 402-619
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  • March 26, 2015
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Anuga FoodTec 2015 Bosch launches redesigned machine concept for individually packaged slices of processed cheese slices down to 13 grams Complete packaging solution for cheese industry

  • High-speed production and precise distribution of processed cheese
  • Full control over the product from forming through stacking
  • Designed to work as stand-alone solution or as part of Module++ concept
Cologne – To meet the growing demands of the cheese industry, Sapal SA, a company of Bosch Packaging Technology, will launch its redesigned DCS 1000 processed cheese conditioner at Anuga FoodTec 2015. The machine has been redesigned to ensure uninterrupted production of individually wrapped slices (IWS) with an output of 1,000 slices per minute. Bosch experts will deliver presentations about the technology each day of the show at the booth.

“The demand for cheese is growing rapidly worldwide, with International Dairy-Deli-Bakery Association projecting a 25 percent growth from 2015 to 2018. The processed cheese market is expected to follow this trend,” explained Louis Monnickendam, senior manager business development at Sapal SA. “The next generation DCS 1000 is the latest in a series of high-speed machines and shows our commitment to delivering solutions that allow producers to capitalize on this growing market.”

Improved sealing accuracy and material savings
A fully redesigned forming group, with now integrated cooling system, provides full control of the product at any given speed. This results in an excellent distribution of the cheese mass and a perfect and precise slice shape even at the lowest slice weight of 13 grams (lowest available on the market). The sturdy designed forming group furthermore allows for a broad span of recipes – from reduced dry matter to non-dairy ingredients – giving manufacturers the flexibility to quickly adjust to changing market demands.

The redesigned sealing process offers greatly reduced, extra thin sealing widths for the transversal sealing enhancing product appearance and ensuring substantial film savings. Regardless of the temperature difference inside and outside the cooling unit, the machine offers full control of the film positioning. In addition the redesigning of the group of knifes has significantly improved the knife life span.

Full control of the product at any given time
One of the main features of this new generation machine is the redesigned distribution drum. Capable of handling and supporting 1,000 slices per minute towards three conveyors, the improved construction ensures accurate alignment of each slice and efficient transportation to the stacking device. The redesigned DCS 1000 is also equipped with a motorized three stack descent device. This ensures that each slice lands in the same position, forming an accurate, vertically stacked profile. Built using Bosch Rexroth's proven technology, each movement is independently driven but fully controllable providing operation flexibility and improving the machine’s user-friendliness.

To learn more about Sapal's latest development visit Bosch at Anuga FoodTec in Cologne, Germany, March 24 to 27, 2015 in hall 7.1, booth D10-E19.

Louis Monnickendam
phone: +41 21 633 55 81

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Christin, Poenisch
phone: +49 711 811-58502
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  • March 24, 2015
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Achema 2015 2,600 capsules per minute: the new GKF capsule filling machine from Bosch New development according to customer requirements

  • High output of up to 156,000 capsules per hour
  • Fast process and product adaptations thanks to highly flexible machine platform
  • User-friendly handling at highest hygiene standards
Frankfurt/Main, Germany – At this year’s Achema, Bosch Packaging Technology, a leading supplier of process and packaging technology, launches the new capsule filling machine GKF 2600. This high-performance machine doses powders, pellet, tablets and liquids, as well as combinations precisely and reliably. An output of up to 2,600 capsules per minute can be achieved. “The newly developed GKF 2600 combines proven and new technologies at higher outputs,” Karl-Heinz Kappes, product manager at Bosch Packaging Technology, underlines. “The machine is equipped with new filling technologies for different products, an optimized drive concept, significantly enhanced sensor technology for process control, as well as a demand-oriented containment concept.” Due to its extended machine platform and very good accessibility, the capsule filling machine can be adapted to fill different products in a very short time. Thanks to these characteristics, add-on modules can also be integrated quickly and easily.

New development with numerous expansion possibilities
The development of the new capsule filling machine is consistently based on the demands of the pharmaceutical industry and profits from the long-term experience of Bosch in capsule filling operations. “With its standard functions, the GKF 2600 fulfills the industry requirements regarding precise and reliable capsule filling. This includes, for instance, an automatic anti troubleshooting (ASB) function, as well as user-friendly handling with improved accessibility of the filling stations,” says Kappes. The optimized containment with more tightly sealed doors further ensures that the highest hygiene standards are maintained during production.

Apart from the standard functions, numerous options are available, such as the new capsule checkweigher KKE 2600 with enhanced product control. Additionally, the GKF 2600 can be upgraded with a feedback loop, which automatically regulates overfilling and underfilling of capsules via tendency control of the KKE. An inspection unit can further be integrated into the capsule filling machine. It conducts weight and quality inspections with x-ray technology and an x-ray sensor. “Reliable micro-dosing of powders is crucial, especially for highly effective products that require an exact medication,” Kappes explains. “The micro-dosing wheel of the GKF 2600 precisely processes products in a filling range of two to 30 milligrams.” Depending on customer requirements and product characteristics, the capsule filling machine can be upgraded for different containment requirements. “The combination of highly developed standard functions and versatile add-on possibilities makes the GKF 2600 a future-proof solution for a broader product spectrum,” Kappes concludes.

Bosch’s technologies are on display at Achema in Frankfurt/Main, Germany, from June 15 to 19, hall 3.1, booth C71.

Karl-Heinz Kappes
phone: +49 711 811-57255
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  • March 11, 2015
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Achema 2015 Bosch Packaging Technology: extensive line competence Eleven launches on one booth

  • Exemplary line concepts for different therapeutic areas
  • Development, production, filling and packaging of solid and liquid pharmaceuticals tailored to customer needs
  • Comprehensive consulting and services before, during and after start-up
Frankfurt/Main, Germany – At Achema 2015, Bosch Packaging Technology, a leading supplier of process and packaging technology, focuses on its line competence. Trade show visitors can expect eleven market launches for the pharmaceutical and biopharmaceutical industries on a floor space of over 1,000 square meters. With a combination of exhibits and multimedia presentations, Bosch showcases exemplary line configurations for different therapeutic areas. “Whether customers need a complete line for the production and packaging of oncology drugs, for treatment of diabetes or gastric ulcers, or a solution for eye drops or cough syrup – Bosch is the competent partner for all pharmaceutical requirements,” explains Christian Treitel, head of pharma business development at Bosch Packaging Technology.

Exemplary lines for solid and liquid pharmaceuticals
Bosch presents line configuration examples for the manufacturing of tablets for diabetes treatment, as well as for capsules that are administered to cure gastric and intestinal ulcers. The new Hüttlin granulation line Granulean, which is available in three standardized sizes, can for instance be connected to the new Manesty TPR tablet presses via suitable handling and transfer equipment. The capsule line comprises precise dosing, amongst others of pellets, as well as filling on the new GKF 2600 capsule filling machine, followed by inspection and transfer to the packaging process.

On the basis of different therapeutic areas and packaging types, three exemplary lines for liquid pharmaceuticals further illustrate Bosch’s line competence. For instance, equipment for all process steps of oncology drugs administered in vials is available: from Pharmatec bioprocess systems to highly precise filling, integration of freeze-drying and capping to external cleaning of vials with the new RAN washing machine. Apart from particle and cosmetic inspection, Bosch also presents a new inspection machine for leak detection. Furthermore, Bosch offers cartoning machines with sophisticated serialization and aggregation solutions for the secondary packaging process.

New developments based on pharmaceutical requirements
An exemplary syringe line shows how customers can efficiently produce, fill and package their drugs for the treatment of autoimmune disorders. Process systems for the production of active pharmaceutical ingredients and a new system for the generation of WFI (water for injection) are followed by formulation and filling on the flexible platform for pre-sterilized syringes with single-use filling systems. The latter can be combined with barrier systems and further equipment such as the new wireless glove tester. Depending on the product, sterilizers with hot water shower or steam/air mixture from Schoeller-Bleckmann Medizintechnik (SBM) can be used. The line is complemented by particle and cosmetic inspection, further downstream equipment and complete secondary packaging solutions.

The manufacturing and filling process of liquid pharmaceuticals into cartridges is illustrated by the therapeutic area of diabetes care. The line starts with water treatment and insulin production systems, followed by market-leading filling and closing machines. Once the cartridges have been inspected, the insulin pens are assembled on the fully automated assembly platform from Moeller & Devicon, before they are packaged, serialized and aggregated. Many further components, such as CIP/SIP systems and SBM equipment sterilizers, can be added to the line. “Depending on therapeutic area and dosage form, customers receive lines that are tailored exactly to their requirements, with ideally aligned machines and systems. At the same time, all new developments are based on pharmaceutical requirements,” Treitel underlines.

Highly flexible line configurations
For ophthalmologic applications, Bosch showcases a Sigpack HSL horizontal flow wrapping machine, which is loaded with vial cards via a Sigpack LDF feedplacer. The eye drops, which have been filled with the blow-fill-seal technology, are packaged and hermetically sealed in aluminum compound film to secure products from water vapor and light exposure. An exemplary animation shows how liquid oral dosage forms such as cough syrup can be filled in glass and plastic bottles. Bosch also offers the suitable process technology for these types of medication, as well as the high purity media systems and product sterilizers that are required for after-treatment. Moreover, all line configurations can be flexibly combined with further inspection devices, handling equipment and secondary packaging machines. The requested serialization features are applied to the packaging before aggregation.

Comprehensive consulting and services
“Beyond machine technology, we support customers with market-specific expertise, as well as detailed project and integration competence,” says Christian Treitel. With additional services and comprehensive consulting before, during and after start-up, Bosch ensures that all customer needs are satisfied. This also includes qualification and validation of the lines. Furthermore, the worldwide training platform Bosch Packaging Academy, which was founded in 2014, offers customers and employees a standardized knowledge pool for the entire Bosch Packaging Technology machine portfolio.

Bosch Packaging Services supports its customers with sophisticated maintenance concepts to achieve the highest machine availability with less downtime and reduced costs. Apart from conducting maintenance activities based on electronic protocols, Bosch offers services such as thermography and cleaning of control cabinets. A large range of modernization and technical audits, as well as remote services help customers to flexibly adapt their existing machines and lines to future market requirements.

Automation technology from Bosch Rexroth
Bosch has set the course for automation technology: the continuous system solution IndraMotion MLC from Rexroth offers a future-proof drive and control technology that also fulfills the growing demands for networked machines and systems on the basis of Open Core Engineering. This way, the automation technology rounds out Bosch’s line competence.

Bosch’s technologies are on display at Achema in Frankfurt/Main, Germany, from 15 to 19 June, hall 3.1, booth C71.

Nicole Koenig
phone: +49 7951 402-648
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  • March 05, 2015
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  • Packaging Technology
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