Uniject Finishing Machine

Uniject Finishing Machine

Uniject Finishing Machines

The Luciano Uniject Model 120/150 Machine, which finishes the processing of the individual Uniject units, can be integrated into a complete Finish Packaging System depending on the requirements of the customer. Secondary operations may include particulate inspection, pouching, pouch collating, cartooning, blistering, checkweighing, bundling, case packing, or a variety of manual or semi-automatic operations.

About UnijectTM : A proprietary product of Becton Dickinson, the UnijectTM is a prefilled, auto-disabled, single-dose injection device specifically designed to prevent attempts at reuse. This product was designed to ensure that the correct dosage is given, and to allow for self-injection in developing countries. First introduced in 2000, the Uniject is now being used worldwide for such drugs at hepatitis B vaccine and tetanus toxoid in Southeast Asia and Africa. Luciano was asked to develop a modular system for performing the various processing functions to finish the packaging of individual Unijects.

Uniject Finishing Machine Model 120/150 Functions and Operations

The Uniject machine processes reels of filled and sealed Unijects. The basic machine performs the following functions:

  • Inspect for presence of fluid
  • Print and apply label
  • Inspect label print and label accuracy
  • Cut individual Unijects out of the reel
  • Reject Unijects that fail inspection
  • Dispense finished, accepted Unijects
The machine will process all Unijects in the reel, including the first leading and the last trailing units. A new reel can be fed in manually without stopping the machine. Continuous motion carries the product through the fill detection and labeling stations. Die cutting is done intermittently, producing four products per cycle at up to 37.5 cycles per minute, for an output of 150 Unijects per minute. The transition 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. Uniject Finishing Machines 02

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The machine is PLC-controlled, and the operator interface is a color-touch screen. This machine is self-diagnostic – if a problem occurs, (e.g. material jam, consecutive inspection failures, etc.), a graphical message display will explain why the machine stopped, thus enabling prompt operator attention. An OSHA compliant safety 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 and was designed to conform within a pharmaceutical production environment. The base machine will be supplied with tooling for one product size, and one unwind stand for coiled Uniject strips.

Optional Accessories:

  • Inkjet printing for lot number/expiration date
  • Second labeling head from front and back labeling
  • Thermal transfer printing for lot number/expiration date
  • Printing presence detection for number/expiration date
  • U.V. label detection
  • Syringe shield gap and presence inspection
  • Fully automated cosmetic inspection
  • Semi-automatic enhanced video particulate inspection
  • Special brand of PLC or controls components
  • Additional reel unwind stands
  • Die sets for additional product sizes
  • Air compressor

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Automatic Uniject Pouching Machine

After the Unijects are labeled, die-cut, and inspected, they can be pouched in a hermetically sealed
foil-laminate pouch in a machine developed by Luciano. The Uniject Pouching Machine is two-lane pharmaceutical grade, four-sided seal machine that uses two (top and bottom) material rolls and servo-controlled motions.
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Pouching Machine Operation

Finished Unijects are transferred from the finishing machine directly onto an infeed conveyor that carries them into the pouch as it is 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.

Special Accesories, Collating and Handling Systems

Special robotic and other handling devices can be integrated to transfer product into carrying puck (for leak detection and automatic particulate inspection), and into and/or out of different pouching, blistering, bagging or cartooning machines for secondary packaging. Special product collating machines are also available.

Product Collating

For applications requiring more than 1 Uniject per pouch. Collating systems can be added at the outfeed of the Model 120/150 Finishing Machine or the particulate inspection module.

Automatic Cosmetic Inspection

A fully automatic cosmetic inspection system consisting of two (or more) vision inspection cameras can be integrated directly onto the Model 120/150 Finishing Machine. The cameras and lighting system are integrated 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:

  • Label placement/presence inspection
  • Lot number/expiration date verification
  • Shield presence and gap inspection
  • Die cut performance

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Uniject Finishing Machines 07 Semi-Automatic Particulate Inspection

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 integrated 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.

Tabletop Filler/Sealer

Ideal for short runs, stability tests, or clinical trial batches, this filling machine can be used on a bench top or in a clear 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 on operator actuation. This Tabletop Filler/Sealer is fully compatible with Class 100 asceptic requirements, including cleanability, support of laminar air flow and corrosion resistance.

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Leak Detection

A leak detection option is available using non-destructive, high frequency, 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.