The Uniject machine processes reels of filled and sealed Unijects. The basic machine performs the following functionns.
The machine will now process all Unijects in the reel, including the first leading and last trailing one. A new reel can be fed in manually without stopping machine.
Continuous motion carries the product through fill detection and labeling. Die cutting is done intermittently, producing, four products per cycle at up to 37.5 cycles per minute, so that 150 Unijects are finished per minute. The transiton from continuous to intermittent motion is handled internally within the machine without loss of leading or trailing products. The machine was designed to use a minimum of compressed air, and the cutting press is driven by a servo motor. The control is by a PLC, and the operator interface is a color touch screen. The machine is self-diagnostic, so that if any problem occurs such as a material jam, consecutive inspection failures, etc., a graphical message display will explain why the machine stopped, to enable prompt operator attention. An OSHA compliant saftey enclosure surrounds the mechanical components, with doors interlocked so that the machine will not run when the door is open. The machine is built of non-corrosive materials, in a design amenable to a pharmaceutical production enviroment. The base machine will be supplied with tooling for one product size and one unwind stand for coiled Uniject strips.
Following the labeling, diecutting and inspection process, the Uniject devices can be pouched in a hermetically sealed foil laminate pouch. This is done in a horizontal dual lane, four-sided seal, pharmaceutical grad machine, using two (top and bottom) material rolls and servo controlled motions
Finished Unijects are transferrered from the finishing machine directly onto an infeed conveyor that carries them into the pouch, as it formed. The two webs of pouch material come together around the Uniject to form a pouch, which is heat sealed and then cut apart from the other pouches. Peelable seal pouches can be made or permanent seal pouches with a tear notch are available. The pouching section runs only when product is present so that material waste is minimized.
The Model 120 / 150 Finishing Machine can be intergrated into complete Finish Packaging Operations depending on the requirements of the customer. Secondary operations may include pouching, pouch collating, cartoning, blistering, checkweighing, bundling, case packing, or a variety of manuel or semi-automatic operations. Luciano Packaging Technologies, Inc. has the staff and resources to provide complete engineering, procurement, and intergration services. We work with each client to ensure that the appropriate equipment is selected for their application needs. In addition, we can provide training, installation, service support, and validation documentation / execution services.
Special robotic and other handling devices can be intergrated to transfer product into carrying pucks (for leak detection and automation particulate inspection), and into and / or out of different pouching, blistering, bagging or cartoning machines for secondary packaging. Special product collating machines are also available.
For applications requiring more then 1 Uniject per pouch. Collating systems can be added at the outfeed of the model 120 of the particulate inspection module.
For manualy controlled particulate inspection, booths with proper lighting and magnification can be provided. A pouch loading fixture is an optional accessory.
A fully automatic cosmetic inspection system consisting of two (or more) DVT cameras can be intergrated directly onto the Model 120/ 150 machine. The cameras and lighting system are intergrated into the carrier belt system to inspect product after it has been die cut, just prior to the automatic reject. This system can be set up to inspect for any or all of the following conditions:
For particulate inspection, a four-camera enhanced video system is used. The system cameras, mounted directly on the machine at the carrier belt section, feed live video footage of the product well during the machine dwell cycle to four off-line monitors that are attended by operators. The product well is enhanced up to 10X on the monitor for easy operator identification of particles. A manual product accept operator at each work station is tied to the automatic reject on the machine. The product is agitated using an adjustable pneumatic vibration system intergrated after the die cutting, just prior to inspection. The cycle time required to allow for adequate manual inspection and decision making is 120 per minute (30 products per operator per minute). Therefore, a machine equipped with this inspection system is designated a Model 120I.
A leak detection opton is available using non-destructive high requency, high voltage technology. This can be incorporated directly onto the machine, just past the die cutting operation, or it can be incorporated into a special transport puck system between the model 120 / 150 machine and secondary packaging equipment
Ideal for short runs, stability tests, or clinical trial batches, this filling machine machien can be used on a bench top or in a clean air hood. It uses the same product dispensing system as the production filler.
At each index, one Uniject is filled and sealed. The machine can produce up to 15 per minute, depending upon operator acuation.
It is fully compatible with class 100 aspectic requirements, including cleanability, support of laminar air flow and corrosion resistance.