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Maker - Product Challenge

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<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

The most significant decision when making ointments is likely to be the choice between automatic or semi-automatic processes for it. This impacts on individual phases of the ointment cream manufacturing process - the water phase and oil phase.

Ointment

<span style="font-weight: 400;">Increasing numbers of products in the pharmaceutical, cosmetic and food industries are delivered in flexible tubes, bottles or dispensers. Automated tube filling machines improve production efficiency by accurately filling, sealing and capping a range of tube-based packaging with minimal operator intervention. For smaller-scale production environments, large filling machinery is impractical and expensive.</span>


<h2>Automatic tube filler for small scale production</h2>
<span style="font-weight: 400;">The FP-10 from IWK is a next-generation tube filling machine that operates at lower speeds, most suited for small scale production. It features 10 workstations that can handle tubes from 10 to 52mm diameter and can accurately dose from between 1.5 ml and 300 ml of product at up to 70 tubes per minute.</span>

<span style="font-weight: 400;">The FP-10 has been designed to allow for rapid product changeover, and all components can be switched out in a little as 15 minutes, keeping downtime to a minimum.</span>

<span style="font-weight: 400;">The FP-10 benefits from the latest servo technology, giving the machine extremely high reliability and minimum maintenance. A new 5.7” touch panel HMI not only displays all relevant process parameters, but also allows profile storage and data recording. Internet connectivity allows for remote diagnostics and servicing.</span>

<span style="font-weight: 400;">Able to fill metal or plastic containers, the FP-10 can perfectly contour seal plastics with hot air and offers double, triple or saddle folding for metal tubes to meet your exact requirements.</span>

<span style="font-weight: 400;">Suitable for use with a wide range of products, the FP-10 can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).</span>

Low speed tube filler

<span style="font-weight: 400;">For scale-up filling of tube packaging for pharmaceuticals, cosmetics and food products, a medium-speed automatic tube filler is required that meets increased demands of speed and volume with high levels of accuracy and minimum downtime. The ability to handle a wide variety of packaging types, and to cap and seal in different ways means additional flexibility that results in increased efficiency.</span>


<h2>Scale-up tube filler for increased efficiency at higher volumes</h2>
<span style="font-weight: 400;">The IWK FP Series is a latest-generation modular filling and sealing machine for tube-based containers. Designed with reliability, ease of use and performance as a priority, the FP Series uses the latest servo technology throughout to provide industry-leading levels of reliability.</span>

<span style="font-weight: 400;">The range features 18 to 64 workstations that can handle tubes from 10 to 63mm diameter and can accurately dose from between 1.5 ml and 700 ml of product at up to 300 tubes per minute.</span>

<span style="font-weight: 400;">The modular design of the FP Series allows it to be configured to your exact requirements, both in terms of operations and functions and floor layout. 5 servo drives (with an additional 4 as options) are at the heart of the oval transport system and offer high level of accuracy together with a robustness that keeps maintenance and downtime to a minimum.</span>

<span style="font-weight: 400;">The FP Series is available with a large range of options that means it can be tailored to your exact requirements. Options include tube feeding systems, in-line checkweighing, frequency welding, droplet dosing and many more.</span>

<span style="font-weight: 400;">Multi-colour tube filling is available and features the IWK patented swing-out quick change system for rapid changeover. Multi-colour fill types include sandwich, deep stripe, surface stripes and core striping.</span>

<span style="font-weight: 400;">The newly designed HMI features a 15” touchscreen control with graphical status reporting and diagnostics, and is fully 21CFR part 11 compliant for auditing and reporting.</span>

Medium speed tube filler and sealer

<span style="font-weight: 400;">When scaling up production of pharmaceutical, food or cosmetic products that use tube containers, increasing speed and throughput without compromising on accuracy and quality are vital. Tube fillers need to be able to handle a wide range of packaging types and allow for rapid changeover to benefit from their flexibility and speed.</span>


<h2>Small footprint, GMP-design medium to high speed tube filler</h2>
<span style="font-weight: 400;">The IWK TFS-E Series benefits from a range of innovations that result in a robust, easy-to-use and maintenance-free tube filling solution for medium scale production.</span>

<span style="font-weight: 400;">The TFS-E Series features 20 workstations that can handle tubes from 11 to 52mm diameter and can accurately dose from between 1 ml and 350 ml of product at up to 220 tubes per minute.</span>

<span style="font-weight: 400;">Designed with flexibility in mind, the TFS-E features a format change over time of less than 25 minutes, and storing and recalling all relevant process parameters to guarantee a vertical start up. All product-contacting parts are swapped out “en bloc” which gives the maximum efficiency whilst allowing for a range of product. The patented IWK dosing system is supremely accurate but also simple to maintain, thanks to Clean in Place in under 5 minutes.</span>

<span style="font-weight: 400;">Able to fill metal or plastic containers, the TFS-E Series can accurately contour seal plastics, and offer a choice of double, triple or saddle folding for metal tubes to meet your needs.</span>

<span style="font-weight: 400;">Suitable for use with a wide range of products, the TFS-E Series can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).</span>

<span style="font-weight: 400;">A wide range of options enables the TFS-E Series to be specified exactly to your requirements. Options include multi-colour filling, tube de-dusting, in-line checkweighing, automatic central lubrication system, and many more.</span>

Medium and high speed range automatic tube filler

<span style="font-weight: 400;">For high-volume lines filling pharmaceutical, cosmetic or food products into tube containers, high speed and throughput must not come at the compromise of fill accuracy and sealing quality. High performance tube filling machines successfully match performance with quality, using a range of technological advances to ensure the maximum efficiency and rapid ROI.</span>


<h2>World’s fastest high efficiency tube filler with advanced features</h2>
<span style="font-weight: 400;">The TFS-80 Series from IWK is a high-performance, next-generation tube filling machine that is most suited for large scale production environments. It features up to 24  workstations that can handle tubes from 22 to 40mm in diameter and can accurately dose from between 2 ml and 220 ml of product at up to 750 tubes per minute.</span>

<span style="font-weight: 400;">The TFS-80 Series is officially the world's fastest tube filler, and yet it’s new weight checking and quality control system guarantees accuracy, reducing tube overfilling significantly. By using a clever modular design, workstations can be retrofitted with ease for maximum flexibility and future expansion, making development of new packaging or product types simple.</span>

<span style="font-weight: 400;">Because it operates with such high performance, the TFS-80 Series has been engineered for reliability and efficiency. Many traditional mechanical actions have been rendered obsolete by the use of servo technology throughout. State of the art bearings with central lubrication system allow for long service intervals, reducing maintenance costs. </span>

<span style="font-weight: 400;">For greatly reduced downtime caused by product changes, fast exchange systems are employed. New motion parameters are automatically set via servo drives in case of product changes. The touch screen panel HMI makes these operations quick and easy, as well as allowing simple monitoring of the machine in use. Internet access allows remote diagnostics, further reducing any downtime.</span>

<span style="font-weight: 400;">Despite the high performance of the TFS-80 Series, it’s been designed to occupy as compact a form-factor as possible, providing maximum flexibility when it comes to your own installation.</span>

High speed automatic tube filler

<span style="font-weight: 400;">Many pharmaceutical products are packed in protective and decorative cartons. Using an automatic vertical cartoner increases the efficiency of the packing operations by taking carton blanks and forming and sealing the carton allowing product to be inserted from the top, and then closing and passing on for final packing, all at high speed. Flexible machines that can handle a range of carton types bring even greater benefits when used in larger scale production.</span>


<h2>Pharmaceutical cartoner with higher speed and flexibility</h2>
<span style="font-weight: 400;">The IWK VC 5 is a high speed vertical cartoner that can be used with wide range of pharmaceutical products and can form and pack up to 120 cartons per minute.</span>

<span style="font-weight: 400;">For increased flexibility the VC 5 offers an extremely fast format change to limit downtime associated with product changeover, thanks to central transport height adjustment and quickly changed carton buckets. </span><span style="font-weight: 400;">For reduced maintenance and an increase in reliability, the VC 5 uses servo drives throughout. This results in increased energy efficiency and reduced noise and vibration. </span><span style="font-weight: 400;">To assist with monitoring and to facilitate easy changeover, the touch screen HMI makes selecting operation easy. The entire machine has also been designed with ergonomics in mind, meaning accessibility is simple and cleaning is quick.</span>

<span style="font-weight: 400;">The base unit has 40 carton carriers and stations, but the modular design means extensions to the can be added, as well as the option of automated product loading and leaflet inserting.</span>

<span style="font-weight: 400;">The flexibility of the VC 5 means a wide array of product can be cartoned, including tubes, blister packs, vial, ampoules, cannulas, pouches, bottles and sachets.</span>

High capacity cartoner for pharmaceutical applications

Most pharmaceutical and cosmetics products are packed in cardboard cartons for protection and branding. The use of an automatic horizontal cartoner increases the efficiency and accuracy of packaging by taking carton blanks that are formed and sealed, allowing the product to be inserted from the side, and then closing and passing on for final packing. Cartoners can be specified with a variety of different cartons and closure systems for maximum flexibility.


<h2>Intermittent horizontal cartoning machines for smaller-scale production</h2>
The IWK SI range of intermittent horizontal cartoners has been designed specifically for smaller-scale production in the pharmaceutical and cosmetic industries. Operating from 45 to 80 cartons per minute, the SI series can be used with virtually any product type, including tubes, blisters, vials, ampoules, bottles, sachets, and cannulas.

The SI range has been designed for ease of use with touchscreen display control and offers simple, tool-free size changeovers to minimize downtime at product change. The machine has also been designed to be easy to access at all points for cleaning or service.

Servo drives are used throughout, increasing reliability and reducing maintenance and a teleservice option is available for remote diagnostics and immediate fault correction, without the need for a service technician on site.

The modular design of the SI range means that options can be specified to meet your exact requirements, including leaflet feeding, different closure options, and a full range of pharmaceutical control options including code-reading and verification systems.

Horizontal cartoner for pharma and cosmetics

<span style="font-weight: 400;">A large number of cosmetic and pharmaceutical products are packed in cardboard cartons for protection and branding. For medium-scale production lines, the use of an automatic cartoner increases the efficiency and accuracy of packaging by taking carton blanks which are formed and sealed, allowing the product to be inserted from the side, and then closing and passing on for final packing, all at a speed matched to the production volume of the line. Modular cartoner systems allow for increased flexibility and tailoring to manufacturer requirements.</span>


<h2>Medium-scale automatic cartoner with a wide range of modular options</h2>
<span style="font-weight: 400;">The IWK SC5/SI5 series is a range of automatic cartoners for medium scale production lines, capable of packaging up to 200 cartons per minute (SC5) or 100 per minute (SI5). </span><span style="font-weight: 400;">The two units are functionally identical except the SC5 offers continuous operation, and the SI5 offer intermittent operation.</span>

<span style="font-weight: 400;">The SC5/SI5 was designed specifically for use in the pharmaceutical and cosmetics industries, and features a fully modular design, allowing machines to be specified to the exact requirements of your production. It also has a short, space-saving footprint suitable for almost all locations, including those where space may be at a premium. </span><span style="font-weight: 400;">A key feature is minimising downtime on product changeover. The SC5/SI5 features quick and simple changeovers that require minimal tools, and the fully accessible design means operators can make the required changes without difficulty. It also means that cleaning and maintenance is straightforward and quick. </span><span style="font-weight: 400;">The modular design concept shows that a large number of options are available, including automatic leaflet feeding, a range of product-type transfer options, code printing, code reading and leaflet presence verification systems, different closure types, and quality control checks.</span>

<span style="font-weight: 400;">For reduced maintenance and an increase in reliability, the SC5/SI5 uses servo drives throughout. This results in increased energy efficiency and reduced noise and vibration. In addition, remote servicing is available with automatic fault diagnosis and correction, without the need for an on site engineer.</span>

Pharmaceutical and cosmetic industry products cartoner

<span style="font-weight: 400;">For high capacity production of cosmetics and pharmaceuticals a high speed cartoner is vital for line efficiency. Automatic cartoners take carton blanks which are formed and sealed, allowing the product to be inserted from the side, and then closing and passing on for final packing. Flexibility is provided by a wide range of options to allow for a tailored packaging solution.</span>


<h2>High performance horizontal cartoner for large scale production</h2>
<span style="font-weight: 400;">The IWK SC series is a high performance, high output automatic cartoner specifically designed for the pharmaceutical and cosmetic industries. Available in 4, 6, and 8 models, these continuous cartoners are able to package 450, 300, and 150 cartons per minute respectively.</span>

<span style="font-weight: 400;">The IWK SC series is designed as a modular system. This means that specifying your exact requirements is simple, but also that future retro-fit is possible with minimum downtime.</span>

<span style="font-weight: 400;">The SC series features all-servo drive train for increased efficiency, smoother performance and reduced maintenance. The SC also features remote teleservicing, allowing for off-site diagnostics and fault clearance without the need for an on-site technician.</span>

<span style="font-weight: 400;">For maximum flexibility, the SC series is able to carton all product types, including tubes, blister packs, vials, ampoules, cannulas, pouches, bottles and sachets.</span>

<span style="font-weight: 400;">Across the range, the SC series can work with cartons from as small as 20x15x50mm up to 165x75x185mm, with a simple and tool-free size changeover to minimise downtime.</span>

<span style="font-weight: 400;">Operation is simple thanks to a touch screen HMI which uses a 3D visualisation to track machine performance, and the entire design is ergonomic to allow easy access for maintenance and cleaning.</span>

Automatic cartoner for applications in pharma and cosmetics

<span style="font-weight: 400;">Cartoners take carton blanks which are formed and sealed, allowing the product to be inserted from the side, and then closing and passing on for final packing. In the production of high volume pharmaceutical and cosmetic products, cartoners need to be able to operate continuously at the highest speeds with the highest levels of accuracy.</span>


<h2>Very high capacity cartoner for large-scale pharmaceutical and cosmetics production</h2>
<span style="font-weight: 400;">The IWK SC3 series is a continuous motion cartoner that can operate at speeds of up to 800 cartons per minute. Designed specifically for the pharmaceutical and cosmetics industries, the SC3 series makes the perfect companion cartoner to the IWK TFS 80-6/8 tube filling machine and is widely used for FMCG products like toothpastes.</span>

<span style="font-weight: 400;">IWK’s experience and quality combines in the SC3 series, to offer the highest performance with the maximum efficiency. The use of servo drives throughout increases reliability and lowers maintenance costs, and the machine has been ergonomically designed to allow quick and easy access for cleaning, maintenance and changeover.</span>

<span style="font-weight: 400;">The central touch screen control offers a complete 3D visualisation of machine status and performance, and is complemented with teleservicing, which allows the remote diagnosis and clearance of faults without the need for a technician to be on site.</span>

<span style="font-weight: 400;">As well as tubes, the SC3 series is able to carton a wide variety of products, including, blister packs, vial, ampoules, cannulas, pouches, bottles and sachets.</span>

High-capacity horizontal cartoner for pharma and cosmetics appliances

It is vital to have precise and long-lasting labels on bottles to avoid any accidents or overdosage. Labels on these bottles are constantly exposed to liquids and everyday handling; therefore, they require special care so that they can stand up to the challenge of remaining intact even after rough use.
<h2>Precise and reliable self-adhesive labeling</h2>
The ETIMA  MLP-3000 is built to provide longer-lasting self-adhesive labeling on various containers, including oval, flat, and cylindrical surfaces with complete precision, and to meet different labeling requirements such as partial position labeling or full-body labeling. Whether they are made from glass, tin, or plastic, the MLP-3000 easily ensures self-adhesive labeling for all materials.

This labeling machine can be formatted to deliver a maximum output of 5,000 containers per hour. Designed with NOVEXX labeling heads and a centering system knows as the ORBITER, this labeller delivers an exceptional performance, even at incredibly high application speeds. Lastly, MLP-3000 is specifically designed for the pharma, chemical, food, and personal care sectors.

Self-adhesive linear labeling machine for bottles

AZO LIQUIDS is the partner you can rely on when it comes to innovative solutions for liquid and semi-solid processes in the pharmaceuticals, cosmetics, food and chemicals industries.

If you are <a href="https://making.com/products/creams">producing a therapeutic cream</a> that prevents, cures or alleviates a disease or injury, a license from a government is needed to sell the product.  The requirements for keeping such a license are quite stringent, looking at – for example- traceability, documentation and hygiene. The products must be safe, and you must be able to have proof of this. What does this mean for the manufacturing process, especially for smaller scale companies? What do you as a producer need to have in place?


<h2>Meeting the targets of the Pharmaceutical Quality System</h2>
In order to get and to be able to keep the pharmaceutical license, most authorized government bodies demand the producer to have a Pharmaceutical Quality System that follows Good Manufacturing Practice. Looking at for example the production, operations must follow clearly defined procedures. All materials and products must be stored under the appropriate conditions established by the manufacturer and in an orderly fashion to permit batch segregation and stock rotation. Operations on different products should not be carried out simultaneously or consecutively in the same room unless there is no risk of mix-up or cross contamination. At all times during processing, all materials, must be labelled or otherwise identified with an indication of the product or material being processed, its strength (where applicable) and batch number. This means almost everything needs to be documented or monitored to reach these standards.
<h2>Automated production when upscaling</h2>
Switching to an automated production line can reduce the risk of cross-contamination and make it easier to meet all these standards. If you want to adhere to these standards, it is rather difficult to do with manual production. Many companies decide to scale up and  a first step could be to install a second processing vessel that will only be used to manufacture the final product, where the other vessel is used for the intermediate product. A cleaning system (CIP) would also make it easier to follow stringent hygiene rules. As you grow, a next step could be the incorporation of machines that automate a part of the process or installation of fully automated plant design to eliminate all manual operations and automate a lot of documentation of the production. Apart from tracking all this information, the product would also be fully traced from the start of the manufacturing process all the way to the packaging, a topic that is at the heart of this pharmaceutical license. A good example of automated plants for creams production, is shown in the video below, of the modular vacuum processing plant of AZO LIQUIDS.

[embed]https://www.youtube.com/watch?v=YJQZ8u-r5Gc[/embed]

How to keep your government license for therapeutic cream production?

Pharmaceutical

The topical route is a convenient route for the self-administration of drugs. But turning a pharmaceutical formulation into an easy-to-use cream involves specialized cream manufacturing equipment. Topical dosage forms are essentially an emulsion of oil and water.  But the ratios can be changed to process it into lotions, ointments, and gels.

Cream

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

Find production technology for Ointments packing, and connect directly with leading machine manufacturers worldwide

Ointments packing

Which ointments packing equipment do you need?