Quick format changes thanks to user-friendly design
Intelligent connection of machine and software
Reliable serialization and application of safety seals
Bosch Packaging Technology, a leading supplier of process and packaging technology, has expanded its portfolio for the serialization of pharmaceutical packaging. In the fight against counterfeit drugs, many countries are about to implement legislation changes for a stricter labelling of pharmaceuticals. Consequently, drug manufacturers require safer and more flexible solutions. “With our serialization concept, we offer customers more than just a machine,” explains Daniel Sanwald, product manager at Bosch Packaging Technology. “Bosch offers the complete package, which also includes the corresponding IT.”
Connection of machine and software The CPS (Carton Printing System) forms the basis of all serialization solutions from Bosch. It has been continuously developed regarding flexibility and user-friendliness. Depending on customer requirements, the system prints 1D or 2D data matrix codes on up to 400 folding cartons per minute. Thanks to an upgrade of the camera system, both codes can now be checked on different carton qualities even more reliably. If the contrast and readability of the data matrix codes do not conform with the required level of quality, the products are automatically sorted out. The machine is easy to operate from the front, so that mechanical components are easily and quickly accessible in case of format changes. An optimized threading of the labelling tape reduces downtime of the CPS 1900 to a minimum.
The CPS systems can be connected to both machine software and company IT in a multi-level process, ensuring that serial numbers are attributed reliably. Therefore, Bosch Packaging Technology has adapted the proven automation technology from Bosch’s automotive sector to the specific requirements of the pharmaceutical industry. “This experience enables us to offer our customers IT solutions that not only process the entire order management; they also control both import and export of the serial numbers,” Daniel Sanwald explains. Depending on country and guideline, the numbers are either allocated centrally or generated by the company. Contract manufacturers in turn receive the numbers from their clients. According to Sanwald, “our IT system is equipped for all three cases. The Bosch machines can also be flexibly combined with systems from other IT providers.” The IT concept has further advantages for production companies: production parameters and data of all packaging lines are clearly visible at all times. “For instance, in the case of unforeseen events like downtime or modification, capacities are automatically re-planned,” Sanwald says. “The connection of our machines with the corresponding IT offers companies a new production foresight.”
Modular design for additional safety Thanks to its modular design, the CPS system can be extended by further modules. For example, a weighing module inspects the weight of each folding carton individually. Existing machines can also be equipped with a Tamper Evident module. The labeller applies additional safety seals across the side flap of the folding carton, thus offering optimum protection against manipulation. Sensor systems carry out safe and reproducible checks of seal presence and correct application. The machine and all applications, such as the camera, are operated via a single HMI (Human Machine Interface). “The operator has a uniform look and feel, and does not need to switch between different HMIs. Moreover, this makes the central audit trail a lot easier,” Sanwald underlines.
Growing global need for serialization According to the Bosch experts, the need for serialization technology will continue to grow over the coming years. Amongst others, 2015 will see the implementation of new guidelines in Saudi Arabia, where drug packaging must be equipped with a data matrix code step by step, followed by serial numbers in 2016. In Brazil, individual batches must be serialized as of 2015, before it becomes obligatory the following year. The U.S. Food and Drug Administration (FDA) aspires to implement a standardized identification for all prescription drugs in form of a 2D data matrix code in a step-by-step approach until the end of 2023. The European Union’s Falsified Medicines Directive 2011/62/EU stipulates coded packaging with a 2D data matrix code and a unique serial number for nearly all prescription drugs, presumably from the first quarter of 2018. With the flexible serialization solutions from Bosch, pharmaceutical manufacturers are well-equipped for all regulatory requirements worldwide.
New lap depositor: Testing and improving of products without production stoppages
Width-adjustable slab former for bar production increases efficiency and minimizes waste
SVE 2520 WR vertical bagger offers high-speed packaging for wide range of formats
Cologne – At ProSweets 2015, Bosch Packaging Technology will showcase its comprehensive portfolio dedicated to the efficient and flexible development, production and packaging of confectionery products. At the show, Bosch will launch its GML03 lab depositor, which is designed to enable candy manufacturers to test new products and bring them to market. Bosch will also present its recently launched roller former for minimized trim, a versatile vertical bagger and robotics solutions designed for difficult-to-handle jelly products.
“The confectionery market is booming – and the diversity and volume of new products coming to market has never been greater,” said Frank Jansen, product manager at Bosch Packaging Technology. “As a result, rigid production lines that cater to a single product are no longer viable. Manufacturers need greater agility to adapt to changing market needs, which is why we are committed to delivering solutions that enhance productivity and uptime while enabling the testing of new products.”
Testing and trialling of products to meet new demands At ProSweets, Bosch will launch its flexible GML03 lab depositor, which has been developed specifically to enable producers of jelly, hard candy, toffee, fondant and other confectionery masses to test small product volumes. This allows manufacturers to upgrade current products and develop new recipes without disrupting their regular production processes. With an exchangeable pump system and a choice of different sizes of servo controlled pistons, the lab depositor is able to process a wide range of product formulas, including mono, one shot, striped and striped with filling. All product touching components of the GML03 are made from stainless steel meeting FDA requirements. By achieving hygienic and authentic production standards experimental results can be easily transferred to existing lines. The lab depositor can be purchased or rented, reducing product development costs and improving time to market.
Precise cutting, minimized product waste For manufacturers of bar products looking to reduce product waste and increase productivity, Bosch will showcase the new WRF 600 Flex slab former. The smooth slab former features easy and tool-free adjustments for precise edge cutting of slabs in different sizes, minimizing or eliminating trim and product waste. As the only machine on the market the WRF 600 Flex allows operators to adjust the width during production process, completely eliminating downtime. This enables producers of cereal, candy, protein and fruit bars to decrease production costs and helps achieve a faster return on investment (ROI).
Simple integration with existing Bosch technology means manufacturers have access to a single-source solutions provider for their entire bar production line.
High flexibility for multiple products and pack styles At ProSweets, Bosch will also exhibit its SVE 2520 WR high-speed continuous motion vertical bagger designed to package many varieties of confectionery and chocolate products. The highly flexible machine is ideal for manufacturers who need to switch between different bag styles, including pillow packs, block bottom, four-corner seal, doy and doy-zip, as well as multiple reclosure and opening features. Designed for intuitive operation to minimize operator error and maximize uptime, the machine features color coding for easy and fast changeovers between different formats. The bagger can be easily integrated with other modules such as dosing units, robotic solutions, checkweighers, case packers and third-party equipment and can be adapted for heat and ultrasonic sealing.
Robotic solutions for jelly products With jelly products representing 25 percent of globally growing confectionery production1, Bosch offers robotic solutions specially tailored to the challenges associated with the handling of delicate products: For individually wrapped jellies, Delta robotic solutions provide vision guided quality inspection to detect and remove substandard products. Sugar coated jellies can be gently picked and placed by a Delta robot equipped with a hygienic minimum-contact gripper that avoids contact with sprinkled sugar. This not only ensures high quality products but also boosts uptime and efficiency across the line.
Tailor-made service portfolio At ProSweets, Bosch Packaging Services will showcase its comprehensive after-sales services portfolio, focusing on solutions that improve packaging flexibility, machine efficiency and productivity. Machine upgrades and modernizations enable customers to flexibly adapt their existing equipment to new market requirements. Bosch demonstrates how tailor-made service packages support customers in achieving maximum output and minimum downtime, ultimately resulting in higher profitability of their packaging machines.
To learn more about Bosch’s complete portfolio for confectionary products, visit us at ProSweets in Cologne, Germany, February 1 to 4, 2014 in hall 10.1 at booth C10/D11.
Joint venture expected to employ some 380 associates
Product portfolios are an ideal complement to each other
Strengthening of global market presence, especially in liquid pharmaceuticals
Mumbai, India / Waiblingen, Germany. Processing and packaging specialist Bosch Packaging Technology and Klenzaids Contamination Controls Pvt. Ltd. are planning a joint venture in India. Both companies signed agreements to this effect on November 28, 2014. The plan is for Bosch to acquire a 49 percent share in Klenzaids, an owner-managed company that produces processing, packaging, and clean-room technology for the global pharmaceutical industry. By setting up the joint venture, the two partners aim to extend their global reach, particularly in liquid pharmaceuticals and packaging machines for clean-room environments. The Klenzaids and Bosch Packaging Technology product portfolios complement each other across the board. In particular, the joint venture will allow the companies to better satisfy Indian customers’ growing demand for complete lines from a single source. Based in Mumbai, Klenzaids generated sales of around six million euros in 2013 and employs some 350 people. Bosch Packaging Technology, which last year achieved global sales of 1.1 billion euros and employs some 5,600 associates worldwide, already has a presence in India through its Verna location in the state of Goa. The joint venture is set to be headquartered in Mumbai and is expected to employ some 380 associates. The plan is subject to the approval of the antitrust authorities. The purchase price for the shares acquired by Bosch was not disclosed.
Better products and services for customers in India The joint venture is being set up primarily to benefit Indian customers. Klenzaids will contribute its expertise in clean-room and processing technologies as well as peripheral systems, and Bosch will contribute its strength in innovative filling technologies. Klenzaids provides customers in the private and public sectors not just with plants, systems, and accessories but also with turnkey solutions: buildings and equipment that a customer can use as soon as they are built or assembled to process and package its particular product. These solutions include laboratories with the highest protection class for use in the field of biosafety.
Profitable growth and value orientation Friedbert Klefenz, president of Bosch Packaging Technology, said: “We already have a long history of trusted collaboration with Klenzaids. The company is known for employing excellent people and for providing high-quality products and services. I am delighted at the prospect of a future together.” Hamish Shahani, managing director of Klenzaids, said: “Joining forces and pooling our resources will give us a stronger starting position in the emerging Indian market. Despite our different regional backgrounds, Bosch and Klenzaids have a lot in common. Both place great emphasis on profitable growth, innovative strength, reliability, a motivated workforce, and strong value orientation.”
Complete lines from a single source Klenzaids is an Indian family-run business with a product portfolio that includes laboratory and transfer systems designed to meet clean-room requirements. These machines are indispensable for the sterile production of liquid pharmaceuticals. One of the company’s USPs is its ability to supply laboratories that meet biological safety class standards 2-4. Class 4 laboratories have to satisfy the highest safety requirements, such as being able to guarantee the absolute isolation of microorganisms from the environment. Among the company’s other strengths are isolators and processing technologies for the production of liquid pharmaceuticals.
Strategically important complement to Bosch’s Goa location Bosch Packaging Technology has been developing, building, and selling vertical and horizontal flow wrapping machines for packaging food as well as filling and sealing machines for liquid pharmaceuticals at its location in Verna since 2012. To date, Bosch Packaging Technology has sold over 1,500 packaging machines to leading brand companies in the food and pharmaceutical industries.
Commenting on the agreement, Dr. Steffen Berns, president of Bosch India, said: “Following the inauguration of our manufacturing unit in Verna, this is the second milestone for our packaging technology business in two years. I am extremely confident that this new partnership will further strengthen our product portfolio and market reach. The activities of both parent companies dovetail perfectly, and our pharmaceuticals unit as well as our customers will benefit immensely from this joint venture.”
Klenzaids Contamination Controls Private Limited, founded in 1978 and based in Mumbai, is a leading supplier of clean-rooms, pharmaceutical machinery, accessories and delivers regulatory compliant turnkey, "design-build” projects to the pharmaceutical and life-science industry. Additional services and training support the customers to comply to manufacturing techniques and practices under international regulatory norms. From its headquarter located in Mumbai with support centers in Delhi, Kolkata, Chennai, Hyderabad and Pune and its manufacturing facilities at Umbergaon, South Gujarat, India, a team of 350 dedicated and experienced employees serve customers in India and in export markets such as United States of America, Canada, Poland, Indonesia, South Africa, Argentina, and Italy.
Based in Waiblingen near Stuttgart, Germany, and employing 5,600 associates, the Bosch Packaging Technology division is one of the leading suppliers of process and packaging technology. At over 30 locations in more than 15 countries worldwide, a highly-qualified workforce develops and produces complete solutions for the pharmaceuticals, food, and confectionery industries. These solutions are complemented by a comprehensive after-sales service portfolio. A global service and sales network provides customers with local points of contact.
The Bosch Group is a leading global supplier of technology and services. In 2013, its roughly 281,000 associates generated sales of 46.1 billion euros. (NB: Due to a change in accounting policies, the 2013 figures can only be compared to a limited extent with the 2012 figures). Its operations are divided into four business sectors: Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. The Bosch Group comprises Robert Bosch GmbH and its roughly 360 subsidiaries and regional companies in some 50 countries. If its sales and service partners are included, then Bosch is represented in roughly 150 countries. This worldwide development, manufacturing, and sales network is the foundation for further growth. In 2013, the Bosch Group invested some 4.5 billion euros in research and development and applied for some 5,000 patents. This is an average of 20 patents per day. The Bosch Group's products and services are designed to fascinate, and to improve the quality of life by providing solutions which are both innovative and beneficial. In this way, the company offers technology worldwide that is “Invented for life.”
Multilayer storage tank for simultaneous use with several sterilizers
Energy savings of up to 40 percent in heating, and 60 percent in cooling
Flexible application with all common sterilizers
With a new patented energy recovery concept for hot water shower sterilizers, Bosch Packaging Technology, a leading supplier of process and packaging technology, enables users to achieve significant energy savings in heating and cooling during the sterilization process. The concept was developed by Schoeller-Bleckmann Medizintechnik (SBM), a Bosch Packaging Technology company. “By re-using heating and cooling energy, the system lowers the Total Cost of Ownership (TCO) – not only for hot water shower sterilizers from Bosch but also for those from other manufacturers. Moreover, it can be simultaneously used on several sterilizers,” explains Isa Alkan, head of sales at SBM.
Significant savings in heating and cooling The self-contained, independent system consists of a multilayer storage tank, which is divided into several temperature zones and firmly piped to the sterilizer via a heat exchanger. The water temperature in the permanently filled storage tank increases from bottom to top. Separation planes prevent the temperature zones from mixing too quickly. The stored energy is used for both heating and cooling of the sterilizer.
The water temperature of the sterilization phase usually is 121 degrees Celsius. During cooling, the hot process water flows through the heat exchanger, where it is cooled by cold water from the storage tank. The water in the storage tank thereby absorbs energy from the sterilizer, and heats up again. By using existing cold water from the multilayer storage, manufacturers can reduce the amount of additional, costly cooling medium. An intelligent control system enables the energy to be stored in the storage tank's different temperature zones. After the sterilizer has been reloaded, the energy in the multilayer storage can be re-used to heat the process water to 121 degrees Celsius.
A continuous repetition of these process steps significantly reduces the required amounts of heating and cooling media. As a result, up to 40 percent of the initial heating energy can be saved. Thanks to an additional heating exchanger integrated in the storage tank, the saving potential even amounts to 60 percent for cooling energy. “Apart from the saving potential in heating and cooling, a lower amount of overall media consumption also leads to smaller tank sizes,” says Alkan. “With these savings, companies contribute to environmental protection and can optimize their 'green' image.”
Efficient processes and easy retrofits Fully automated controls enable operators to comprehensively control and efficiently configure the energy recovery concept. Furthermore, an operator control device, designed by SBM, ensures that the energy recovery concept can be activated and deactivated at any time, independently from the sterilizer's controls. In case a customer requires simultaneous usage with several sterilizers, additional heat exchangers can be piped to the stationary storage tank. SBM also offers a retrofit package for existing machines, consisting of engineering, delivery, installation, start-up, documentation and qualification according to current pharmaceutical standards.
At Achema 2015 in Frankfurt/Main, Germany, Bosch will present the new energy recovery concept to industry professionals for the first time (hall 3.1, booth C71).