Increased energy efficiency through energy-saving components and measures for heat recovery
Standardized conveyor belt sizes for optimal adaptation to customer processes
Duesseldorf, Germany – At Interpack 2014, Bosch Packaging Technology, a leading supplier of process and packaging technology, presents the new 6000, 7000 and 8000 series of the HQL drying and sterilization tunnel. This new generation of tunnels is an energy-saving and especially flexible advancement of the proven HQL series for sterilizing and depyrogenizing pre-cleaned ampoules, injection and infusion bottles, as well as cartridges and syringes.
The modular design of the HQL series ensures a customer-specific tunnel arrangement. Each sterilizing and cooling module contains the entire technology for the respective process step. “The modules can now be variably put together. This allows the new series to be flexibly integrated into different line concepts,” Matthias Angelmaier, product manager at Bosch Packaging Technology, explains. In addition, the new design facilitates access to critical areas such as HEPA filters, which can be easily replaced, thus simplifying maintenance of the tunnels.
Savings in energy and space Pharmaceutical manufacturers profit from the increased energy efficiency of the new HQL series. In contrast to most sterilization tunnels, the new series requires less energy for electrical heating and ventilation due to an optimized airflow and measures for heat recovery. A flexible pressure zone concept ensures increased process safety by adapting tunnel pressures in the different zones to customers' requirements. The new tunnels are further characterized by a reduced overall tunnel size, making them shorter and more space-saving than the previous series.
Three standardized conveyor belt sizes The new tunnels are available in three standardized bandwidths of 600 respectively 800 millimeters for the HQL 6000 and 7000 and 1 200 millimeters for the HQL 8000, which is on display at Interpack. With its different sizes, the drying and sterilization tunnel can be flexibly adapted to different requirements. “Based on the physical properties of our customers' packaging material we calculate, which tunnel modules are adequate for their processes,” Angelmaier explains. This subsequently facilitates safe process validation and documentation. “The HQL 8000, for instance, with its broad conveyor belt and several sterilizing and cooling modules is suited for large glass containers and downstream filling machines with high output.” The horizontal transport belt made of a stainless steel wire mesh makes sure all freestanding and non-freestanding containers are transported through the HQL tunnel gently and without abrasion.
Bosch's technologies are on display at Interpack 2014, Duesseldorf, Germany from May 8 to 14 in hall 6, booth A31 – C58.
New thermoforming solution for enhanced output and versatility
PET blowing machine produces wide range of container shapes
Carousel filling machine offers easy format changeovers and maintenance
Duesseldorf, Germany – At Interpack 2014, Bosch Packaging Technology, a leading supplier of processing and packaging solutions, will highlight its comprehensive range of filling and packaging equipment for liquid and viscous food, including three innovations tailored to the dairy and baby food markets with their sensitive products. The TFC 5532 thermoform, fill and seal machine with a unique labeling system offers customers high output and design flexibility for their hygienic packaging applications. For shelf differentiation purposes, the new BLO linear PET container blowing machine allows both dairy and beverage producers to package their products in a wide range of container shapes, styles and sizes. In addition, Ampack GmbH, a Bosch Packaging Technology company since October 2012, has developed a new generation of the KF 2/4 carousel filling machine to offer simple changing between bottle formats, cup formats and pack styles and ensure easy access for machine maintenance.
“With competition for consumers on the increase, manufacturers demand a technology that will enable them to quickly switch between products or pack styles on the production line,” says Robert Fesl, head of sales for product lines thermoform and pouch at Bosch Packaging Technology. “As a result, we focused on developing systems that provide design flexibility and production efficiency while also helping speed up the time to market.”
Adding speed and versatility to thermoforming lines For producers in the dairy or baby food industry aiming at increasing their output, Bosch launches its TFC 5532 for liquid and viscous food such as yogurts, desserts and fresh products which require extended shelf life (ESL). The machine's extended 4x6 cup configuration enables a high output of up to 43,200 cups per hour and handling of various cup sizes ranging from portion packs up to dessert cups. The TFC 5532 is available for clean and ultra-clean hygienic packaging. In addition, it can handle hot-fill applications and products with particulates of up to 25 millimeters in diameter.
A core feature of the TFC 5532 is Bosch's patented in-mould labeling system, which minimizes the TFC's space requirements. In only one step 24 single labels are created and then fed in parallel into the machine. The system also enables tool-less changeovers to ensure more flexible production and short downtime.
The machine's ergonomic, compact design and low height facilitates access to all parts, thereby simplifying cleaning and maintenance. Its hygienic design is further enhanced with the positioning of drives above the cup transport area. An additional benefit of the TFC 5532 is its semi-enclosed tunnel with overpressure of filtered air, maintaining the required hygienic level during product filling to avoid recontamination.
PET blowing for on-shelf differentiation and efficient production For dairy and beverage producers wishing to clearly differentiate their products at the point of sale, Bosch is launching its BLO linear PET container blowing machine. Featuring a maximum speed of up to 35,000 containers per hour and the ability to handle container volumes of 60 milliliters to 2 liters, it offers flexible production of a wide range of container shapes and styles. When combined with aseptic filling technologies from Ampack, the equipment can be used for hygienic applications, including dairy-based yogurt and coffee drinks, alongside mineral water and beverages.
The BLO has been created to minimize PET material use and energy consumption. By rotating the preforms during the heating stage equal heat distribution on every material surface is ensured, allowing for the production of thin-walled containers. The BLO produces lightweight containers with the smallest bottle neck rims on the market, reducing the amount of material required and costs. With its intermittent motion and step-by-step production feature, the BLO heats only a few preforms at a time. This prevents possible product jams during the production process, resulting in reliable operation and maximum uptime.
The BLO's unique linear machine concept and open-machine design facilitate maintenance and operation procedure. For further cost savings and high flexibility to produce a wide variety of shapes, the machine enables simple, quick and tool-less format changeovers, as only a few moulds need to be changed in the blow-moulding module. In addition, other modules and machines can be easily integrated with the BLO machine.
New design of aseptic carousel filler with high degree of flexibility Ampack also launches the KF 2/4 carousel filling machine for the aseptic or ultra-clean filling and closing of bottles and cups. The machine fills liquid products, including those with higher viscosity, fibers and particles such as fruit yogurts, milk drinks, teas, coffees, protein drinks, baby food and clinical nutrition products. Capable of handling cup and bottle sizes from 100 to 1,000 milliliters, the carousel filling machine can reach speeds of up to 10,000 bottles per hour for 200 milliliter bottles.
The carousel filler offers greater flexibility compared to linear filling machines as it enables quicker changeovers between formats and pack styles, such as bottles and cups, in a variety of sizes. This can be attributed to its servo motor concept, which facilitates adjustment to different formats, as well as to its new gripper system that feeds and inserts bottles into the machine's transportation system and outfeeds the filled and closed bottles.
In addition, the KF 2/4 carousel filling machine includes a separate platform for its sterile air unit ensuring filters, pipes and sensors can be effortlessly reached for maintenance. Large doors around the filling machine further simplify monitoring of the filling process as well as maintenance.
For product quality assurance, the machine features a dosing system by inductive flow meter (IFM) and a unique filling valve developed and manufactured by Ampack. Due to the rotary valve design the filler allows fruit, cereals or pulps to pass through. When it closes, its sharp edge cuts the particles instead of crushing them, thus avoiding dripping and preventing any hygienic issues. Compared with mechanical versions, the servo driven stations provide much more flexibiltiy and enable a safe and simple format change via recipe controlled actions.
Bosch's technologies will be on display at Interpack 2014, Duesseldorf, Germany from May 8 to 14 in hall 6, booth A31 – C58.
Two-day industry meeting with around 100 participants
New center of competence for development and process optimization
Expert lectures and discussions from research and industry
Schopfheim/Waiblingen, Germany – On February 19 and 20, 2014, Bosch Packaging Technology, a leading supplier of process and packaging technology, held its Pharma Solid Symposium in Schopfheim, Germany, which gave occasion for the opening of the pharmaceutical laboratory. The international conference offered industry experts an opportunity to comprehensively inform themselves about current trends and developments in the manufacturing and processing of solid dosage forms. “We can look back on two exciting and successful days, during which top-class speakers provided our international guests with up-to-date industry knowledge. In addition, our diversified program provided sufficient room for personal exchange, as well as the chance to get to know our site in Schopfheim better,” explained general manager Martin Gross.
Inauguration of new laboratory Martin Gross and his guests inaugurated the new laboratory during a tour of the premises on the first day of the event. The new facility combines the pharmaceutical portfolio focus areas of the German Bosch Packaging Technology sites Schopfheim and Waiblingen with the British site Knowsley in one center of competence. “We have consistently expanded our laboratory over the past years. Now we offer our customers the appropriate services and machines for all stages – from development to production of their solid pharmaceuticals,” Martin Gross explained. Ten machines from the Hüttlin and Manesty product portfolio, as well as from the site in Waiblingen, are available for tests in an area of more than 300 square meters. The wide range of equipment covers all process steps in the production of solid dosage forms: from mixing, drying, granulating and coating of fine particles and pellets to pressing and coating of tablets and filling of capsules.
Bosch Packaging Technology's pharmaceutical laboratory concept enables customers to test machines and formulations on-site. Bosch experts are on hand to support them during the entire development process of their pharmaceuticals, right through to the start of production and beyond. Additional laboratories for trials and feasibility studies are being established at different sites around the world. In the recently opened customer center in Waiblingen, experts assist pharmaceutical manufacturers in familiarizing with Bosch capsule filling machines.
Concentrated expert knowledge The second day of the symposium focused on lectures and a panel discussion. After the welcome address by Ralf Schmied, director of product area Pharma Solid in Waiblingen, representatives of leading pharmaceutical companies and renowned research institutes reported on new procedures and challenges in the production of solid dosage forms. Speakers included delegates of Hoffmann LaRoche, Capsugel and Excella, as well as the Heinrich Heine University of Düsseldorf, the Johannes Gutenberg University of Mainz, and the Ernst Moritz Arndt University of Greifswald.
The speakers explored a range of new trends and developments in the fields of micro dosing, nanoformulation, biopharmaceuticals and containment. The subsequent panel discussion, moderated by Dr. Martin Opitz, senior market expert from Bosch Packaging Technology, provided the opportunity to debate and reflect the presented topics. “We are very satisfied with the outcome of the Bosch Pharma Solid Symposium 2014,” Dr. Martin Opitz emphasized. “The active participation in the discussions showed how exciting it can be to look upon current topics from different perspectives. Once again, our guests also gave us valuable food for thought.”
Intermittent horizontal cartoning machine for diverse products
Equipped with the latest servo and safety technology
Proven technology with reduced investment
Duesseldorf, Germany – At Interpack 2014, Bosch Packaging Technology, a leading supplier of process and packaging technology, presents the new CUT 1405 cartoning machine – a consistent advancement of the CUT 120 which has proven successful for many years. The new horizontal cartoning machine offers higher flexibility as well as the latest servo and safety technology at reduced costs. “With the new CUT 1405, we are demonstrating our expertise in the area of secondary packaging,” explains Daniel Sanwald, product manager at Bosch Packaging Technology. “As with all our cartoning machines, this new development is based on standard modules that can be flexibly combined, depending on product and packaging type. At the same time, line suitability is granted.”
High flexibility for various products The new CUT 1405 is characterized by a flexible choice for the appropriate in-feed systems, formats and closure options. It can safely and gently handle different carton sizes and packages a wide variety of primary packaging such as bottles, vials, syringes, ampoules, tubes, blisters and trays as well as bags, stick packs and sachets in folding cartons. Inserts to single and combination products such as spoons or outserts can also be integrated into the modular in-feed system. With its quickly exchangeable modules for tuck-in, glue and combination closures, the machine can be flexibly used for various products and line combinations. In addition to pharmaceuticals, the new CUT 1405 is also especially suitable for the packaging of cosmetic and food products.
New in-feed modules and optimized conveyor technology The intermittent cartoner can be equipped with diverse in-feed systems, ensuring maximum flexibility for customized line concepts as well as the packaging of different products and product combinations. The CUT 1405 further features an optimized conveyor technology of the folding carton magazine. To prevent the cartons from getting caught, they are transported into the magazine by a lifting motion of the rake. Thanks to the patented folding carton carrier, the individual cartons maintain their shape as the intermittent transport system moves them through the machine. This prevents damage to the product and ensures precise packaging results.
A mechanical gripper arm carries out leaflet in-feed, which is directly assigned to each product. A shift register checks and follows all products, to ensure that leaflets are only processed further if the outcome of all test results is positive. “This technology has been successful for over ten years and was further optimized for the CUT 1405,” says Daniel Sanwald. Thanks to excellent accessibility, the folder unit can be conveniently operated from the front and, if required, also swivelled out.
Minimum maintenance effort, maximum safety With less hardware components in the control cabin, the new servo technology reduces the need for maintenance while the HMI (Human Machine Interface) allows for easy handling. The operator can quickly localize machine disorders via error messages and resolve them using the automatic troubleshooting guide. All format data is individually stored, enabling easy and quick format changeovers and a safe re-start of the machine. With its wide choice of in-feed systems, the new Bosch cartoning machine can be flexibly adapted for all packaging formats for the pharmaceutical, cosmetic and food industries. Optional serialization, aggregation and tamper-evident modules ensure additional safety, taking into account current guidelines and safety standards.
“The new development is based on the established and proven technology of our CUT 120 horizontal cartoning machine which we have upgraded with the latest state-of-the-art sensor, software, servo and safety technology as well as other features, leading to significant cost reductions for our customers,” Daniel Sanwald concludes.
Bosch’s technologies are on display at Interpack 2014, Duesseldorf, Germany, from May 8 to 14, booth A31-C58.