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micro-dosing-system-2

Micro-dosing-system

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Batch

Continuous

In pharmaceutical manufacturing, maintaining sterility and precise dosing during packaging is crucial to ensure product efficacy and compliance with industry standards. Consistency and accuracy in filling and sealing processes are necessary to meet these stringent requirements.
<h2>Ensures precise dosing and secure sealing</h2>
The PPH system by Harro Höfliger is designed for the production and filling of four-edge sealed bags with pharmaceutical powder and bulk goods. The packaging film is printed in-line and transported for three-edge sealing. Bags then undergo a dosing process with 100% weight inspection before final sealing. This system ensures high precision in dosages ranging from 1 mg to 500 mg, across three dosing stations. The complete process occurs within a GMP-compliant, protected production room. Integration of micro-dosing systems and the ability to manufacture various product variants make the PPH suitable for diverse pharmaceutical applications. The downstream cartoning machine further packages the bags into folding boxes, ensuring a seamless production workflow.

Pharmaceutical powder bag filling system

Bagging is the process of packaging measured portions of a product into bags that protect it from spoilage, enable easy and safe transportation, and secure the product against tampering and pilferage. The choice of bagging equipment depends on the desired mass or volume per bag, the flow characteristics of the product, and bag construction and design. Bags vary in size from small sachets to bulk flexible containers. Bagging systems are often the last processing step that is generally integrated into a production line.

Bagging

Blending

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

Sealing

Weighing

Powder

solid

Industrial

In pharmaceutical production, the precise and efficient micro-dosing of active ingredient powders into inhalation blisters is critical. This involves maintaining accuracy and consistency while ensuring operator safety, especially when handling highly-toxic substances.
<h2>Form, fill, and seal inhalation blisters</h2>
The SSP2 is a small-scale system by Harro Hoefliger designed to form, fill, and seal blister strips for inhalation products. It operates fully-automatically, utilizing either drum dosage for partial cavity filling or membrane dosing for complete cavity filling. The SSP2's versatile filling methods accommodate varied production needs with fill rates of up to 900 fill volumes per minute using membrane dosing. The compact design ensures minimal setup space, making it ideal for facilities with space constraints. Additionally, its integrable containment and regular product quality inspections ensure safety and reliability, even when processing highly-active powders. The SSP2 is mainly used in the production of dry powder inhalers, forming aluminum blister strips that can be further processed and packaged using downstream machines.

Micro-dosing system for inhalation blisters

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

Industrial inspection equipment is used for checking compliance with health, safety, and quality control standards. For that reason, inspection systems are most commonly utilized in the food and pharmaceutical industry but, they are also used in other industries too. Inspection solutions are often integrated into a production process or production line. Visual inspection systems perform checks to detect variation in size, shape, and color and ensure the presence of labels and closures. Check-weigh systems help ensure that product packages are not under or over-filled. Metal detection systems can help guard against the presence of foreign objects in product containers and X-ray inspection equipment is used to detect physical defects and to ensure high quality package seal integrity.

Inspection

In pharmaceutical manufacturing, achieving precise, high-speed blister filling of dry powders is a critical challenge. Ensuring accurate dosages, maintaining sterility, and minimizing contamination are constant concerns during this process.
<h2>Efficiently form, fill, and seal blister cups</h2>
The MSP by Harro Hoefliger is a high-capacity production system designed for commercial blister filling. This solution allows for the formation, filling, and sealing of up to 2,400 blister cups per minute. The system offers integrated drum and membrane dosing options, enabling precise micro-dosing of powders. Drum dosing allows for partial cavity filling, while membrane dosing ensures 100% filling of blister cavities. The design prioritizes containment with enhanced operator protection and easy maintenance. The compact size reduces required setup space, making it ideal for facilities with limited room. Additionally, the MSP includes downstream machines for assembly and end-packaging, ensuring a seamless production line. The machine's versatility and high output rates make it suitable for various pharmaceutical applications, particularly in the production of aluminum blister strips for inhalers.

Commercial blister filling solution for dry powder

Entry level

Manual

In pharmaceutical development, accurately dosing minimal quantities of powder is crucial. Determining product attributes and processes with precision requires reliable and reproducible methods for filling test capsules or vials with exact powder measurements.
<h2>Doses minimal quantities of powder accurately</h2>
The Tamping Pin TT by Harro Hoefliger is a compact, hand-held lab device designed for filling capsules and vials with pharmaceutical powders. It is particularly useful in the early stages of pharmaceutical development or designing dosing formats. Using a metering disk, the device can dose powder quantities as small as 500 mg or more. The fill volume depends on the hole and the height of the disk. The device boasts a dosing volume range of 50 - 1,385 mm³ and can handle particle sizes from 60 - 150 µm. Operators can achieve approximately five doses per minute, making it both time-efficient and reliable. The Tamping Pin TT supports reproducible and comparable trials and can be retooled for various dosing methods, ensuring versatility in lab applications.

Powder dosing for lab and galenics

In industries such as food, pharma, and dairy, precise dosing of powder substances is critical to ensure consistency and quality. Traditional methods may fail to achieve the required accuracy, leading to potential waste and variations in production outcomes.
<h2>Achieve precise dosing down to the gram</h2>
The Dinnissen Feeder Valve paired with the Micro Dosing System is a highly accurate dosing solution designed to meet stringent production needs. The system offers dosing accuracy up to one gram, making it ideal for applications requiring extreme precision. It operates as a butterfly valve powered by a single drive unit and comes with load cells for both loss-in-weight and gain-in-weight measurement, enabling it to handle small and large quantities efficiently. With a production capacity ranging from a few kilograms to tens of tons per hour, it caters to various sectors such as food, pharma, dairy, and feed & aquafeed. The compact and easy-to-clean design minimizes product residue, ensuring quick maintenance and reducing downtime. It is energy-efficient and can be used in batch as well as continuous weighing applications. Validated by major producers of milk powder, cocoa powder, creamers, and sugars, this system guarantees reliability and high performance.

Micro dosing system for precise powder weighing

Pharmaceutical companies developing innovative drug delivery systems and single-use disposables face the challenge of filling and assembling these complex products. They require tailor-made automated solutions to meet stringent industry standards and handle product complexity.
<h2>Automate filling and assembly processes with precision</h2>
The Pharma Custom Automation Solution by Comecer is designed to meet the specialized needs of filling and assembling drug delivery devices and single-use disposables. In collaboration with select technology providers, Comecer develops proprietary solutions or customizes existing ones based on specific client requirements. Key features include microdosing of liquids and powders, employing technologies like micro-auger systems, servo-driven micro pipetting, and custom volumetric pumps. The use of anthropomorphic robots enhances the precision and flexibility of these solutions. Comecer's systems are ideal for applications such as dual chamber syringes, dry powder inhalers, IV bags, and double chamber bags. With performance test studies ensuring the optimal choice of technology, the solutions adhere to aseptic and containment standards, thereby protecting products, the environment, and employees.

Custom automation for drug-device filling and assembly

Assembly platforms combine different parts into one final product. Components are inspected for quality and joined or affixed together into the goods. Assembly lines automate the process to ensure consistent quality and integrate into other technologies, such as packaging equipment. But a primary consideration for assembly solutions is their capacity to scale manufacturing processes. Assembly platforms must be adaptable to your long-term volume requirements.

Assembling

The essential objectives of containment systems are personnel protection and preventing the release of toxic or infectious material into the environment. Containment is also used to prevent a product or sample from contamination by the external environment. In the chemical and pharmaceutical industries, containment solutions are used to protect the personnel from the leaking of airborne particles of hazardous substances, as powders or liquids are handled or transferred during processing.

Containment

liquid

In radiopharmaceutical production, precise micro-dispensing of isotopes like Lu-177 and Ac-225 is essential to ensure accurate dosages and patient safety. Achieving high accuracy in dispensing these isotopes can mitigate risks and support reliable treatment outcomes.
<h2>Ensures high accuracy in isotope dispensing</h2>
The MIKROS is a specialized micro-dispenser designed for radioactive isotopes such as 225Ac and 177Lu. It can dispense very small volumes, ranging from 10 μl to 5000 μl, with high accuracy, making it ideal for pharmaceutical environments. The system uses pipette tips for Tecan and has a barcode reader to identify vials before they move to the vial transfer system. The dispensing unit operates with two TECAN modules that move via a motorized sledge, filling conical 2 ml and flat bottom 10 ml DIN ISO 20 vials with the radio fluid or diluent as needed. Additional features include a crimping unit for stopper handling and a vial transfer system equipped with a mechanical arm and drip tray. Provided by Comecer, the MIKROS also includes a load cell for weighing vials, ensuring precise dosage control. It is suitable for use within cleanroom environments given its design for easy management of cleaning activities.

Micro-dispenser for lu-177 and ac-225

Dispensing

In production environments where precise dosing of sensitive granules or powders is required, maintaining consistency is paramount. High dosing accuracy is essential to avoid material wastage and ensure product quality.
<h2>Delivers precise doses with minimal dispersion</h2>
The Microdosing System SW 701 by Collischan offers a highly accurate dosing solution for granules and powder. With a resolution of 10 µg and a digital adaptive control algorithm, it achieves dosing tolerances up to 0.1 mg. Its versatile design accommodates a broad weight range, eliminating the need for changing formatted parts. Unlike gauge fillers, the SW 701 minimizes shearing forces to process sensitive materials effectively. Each dosing cycle includes a check-weighing process to ensure accuracy. The system has a modular setup for customization based on specific product, space, and performance needs and supports a weighing performance of up to 30 fillings per minute. Made exclusively from stainless steel, the SW 701 is easy to clean and maintain, ideal for various industrial applications, including food, pharmaceutical, and chemical industries. Additionally, it features synchronization capabilities for integration into larger packaging lines and explosive-proof design options for compliance with rigorous safety standards.

Microdosing system for granules and powder

In animal feed production, ensuring precise incorporation of vitamins, additives, and trace elements is crucial for maintaining nutritional standards. Achieving such accuracy can be challenging due to the tiny quantities involved and the need to avoid contamination and dosing errors.
<h2>Automate precise dosing and reduce manual errors</h2>
The Micro-dosing System from Bühler is designed to proportion and feed essential ingredients such as vitamins, additives, and trace elements into your animal feed with high precision. This system offers a dosing and weighing accuracy of 0.1% of the scale capacity, ensuring that formulations are accurate. You can manage automatic proportioning of up to 20 different micro-components. The system is built with stainless and electro-polished steel parts to ensure superior sanitation and minimize contamination risks. Its dust-free bin-filling unit and complete bin discharge further reduce the risk of contamination. Additionally, the system's automated processes mean operators will handle ingredients less frequently, reducing human error and manual labor needs. It is ideal for producing premixes, compound feed, aqua feed, and pet food.

Micro-dosing system for animal feed additives

Depositing equipment is a very common production line process in the food industry. Whether you want to make muffins or jellies or garnish and decorate cakes, all of this is impossible without the depositing step. Depositing is a form of extrusion used primarily to produce pieces of dough that will be further processed to create several food products. The dough is passed through a depositing machine and poured in equal parts from holes in a die plate with nozzles or a conveyor belt. But that’s not all. Depositors are also used to fill, layer, or cover your food items with other ingredients before proceeding to the next step of the production process which is usually packaging.

Depositing

Portioning

When working with plastics in injection molding, blow molding, or extrusion, ensuring precise additive feeding is crucial for maintaining product quality and consistency. Achieving high accuracy, dependability, and repeatability in additive dosing can be challenging without the right equipment.
<h2>Ensures precise additive feeding</h2>
The DD Series Digital Doser System by AEC features a variable speed DC drive motor and dosing disc that accurately feeds pellet or powder additives into the processing machine's throat at a predefined rate. Its precision design and closed-loop control system guarantee high accuracy and repeatability. The system allows easy material changeover by releasing two quick-connect clamps and removing the additive station. An optional spare station enables immediate changeover, reducing downtime and enhancing safety. Available in the DD2 configuration, this system supports dual additives at different rates, offering flexibility based on specific needs.

Digital doser system for plastics additive feeding

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

In water treatment industries, achieving precise mineral balance is critical. Challenges arise when ensuring consistent mineral content and maintaining water's beneficial properties, particularly after processes like reverse osmosis that strip natural minerals.
<h2>Produces mineral-balanced water continuously</h2>
The EASY.RM system by A Due is specifically designed for in-line micro dosing of salts and flavorings, suitable for producing mineral water, flavored water, and functional water variants such as alkaline or curative water. The system efficiently manages all phases of mineral water recipe execution: dissolving, dosing, and mixing various ingredients (flavors, salts, acids, vitamins, natural extracts, lemon juice, sugar substitutes, powder milk or cacao) in different physical states and packaging forms. EASY.RM includes safety filtration for undissolved salts and final disinfection using UV lamps, ozone, or thermal treatment, ensuring the water meets the desired mineral content. The system offers continuous, automated operation and in-line control of pH, conductivity, and flow rate, with capacity ranging from 10,000 to 100,000 liters per hour per unit.

Water remineralization system for mineral and flavored water production

Industrial disinfection equipment use antimicrobial agents to destroy microorganisms found on machines, floors, walls, and other surfaces. In industry, disinfection of machinery and the production area is important to prevent product contamination which may lead to spoilage and health hazards for workers and the consumer. The choice of industrial cleaning equipment depends on the level of disinfection needed, the sanitizing agent, the size of the area or objects to be treated, and the suitable method of treatment such as sterilization, pasteurization, exposure to ultraviolet light, or chemical fogging.

Disinfection

Industrial filtration equipment separates solid matter from liquid by using a filter medium. The filter allows only the fluid to pass through but retains the solid matter. The choice of filtration equipment depends on the particle size, the consistency of the mixture, and the nature of your product.

Filtration

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

Micro-dosing powders of high-value food or chemical products can be challenging when high precision and zero error is required. You need a highly accurate and efficient dosing solution of relatively large quantities of micro-ingredients which can meet the the relevant ISO standards.


<h2>Save time with optimal dosing accuracy</h2>
Alba’s Dosing system DUPLEX is a gravimetric microdosing system which enables the fast dosing of small amounts of powders. It has unparalleled precision with 99.8% accuracy making it ideal to for implementing a good quality system. Its modular design also allows for a great amount of flexibility when it comes to specific process requirements.

Fast gravimetric powder microdosing 50 - 200 g is configured with a duplex or two-tier dosing technology. It requires a dosing time only between 8-12 seconds which is dependent on the characteristics of the material. This allows fast and accurate dosing of relatively large quantities from 50 - 200g of material. It is also equipped with a check-weighing function for the ejection of overweight dosages. This makes it particularly suitable for filling applications with zero tolerance to non-conforming end products.

Fast gravimetric powder microdosing 50 - 200 g

Powders and granules are commonly dosed for the manufacturing of pharmaceuticals, nutraceuticals and high-value foods. Highly accurate dosing and tight sealing is crucial in these production processes to maintain product quality and avoid any errors. You thus need a dosing solution which is made to measure micro-ingredients accurately while being able to meet the strictest requirements of pharmaceutical industry.


<h2>Highly accurate and efficient dosing system</h2>
Alba’s Dosing system MILLI is a gravimetric dosing system which can help you achieve fast and highly precise dosing of free-flowing powders and granulates. It has a dosing capacity of 1-100g depending on the characteristics of your powder. It can be used both as a stand-alone device or incorporated in programmable logic controlling systems.

The gravimetric powder microdosing 2 - 100 g has a modular design which makes it very flexible to be customised according to your specific needs. Its adaptive control algorithm adjusts the frequency of the vibrating feeder by keeping a constant check the flow of material and weight. It thus guarantees high accuracy throughout the dosing range. It has extremely accurate dosing units which only requires a dosing time of 7 – 15 seconds. It is also certified to be used in explosive zones 21 and 22.

Gravimetric powder microdosing 2 - 100 g

If you need to process high value food, pharmaceuticals or chemicals, there is no room for error when measuring. Having a reliable measuring equipment to measure small amounts of powders is crucial to maintain product quality. This is important to avoid incorrect testing results or poor product quality. An efficient and carefully calibrated measuring system is required by most of the relevant ISO standards and essential to achieve accurate results.


<h2>Increased efficiency and accuracy during microdosing</h2>
Alba’s Dosing System Micro allows fast and high precision dosing of free-flowing powders and granules, ensuring that dosing is no longer a bottleneck in the production process. It can be used as a stand-alone device or incorporated in programmable logic controlling systems. It is highly accurate, when dosing and storing small amounts of powders with a dosing capacity starting from 200 mg onwards.

The gravimetric powder microdosing 0.400 - 2 g is configured to handle challenging micro-ingredients while reducing wastage and increasing production. It has a modular design allowing great flexibility when it comes to specific process requirements. It is equipped with extremely precise dosing units making it highly efficient. These units can be used for precise powder dosing in processes that can allow a dosing time of 7 – 15 seconds. It keeps a constant check on the flow and weight of the material fed. Its adaptive control algorithm adjusts the frequency of the vibrating feeder.

Gravimetric powder microdosing 0.400 - 2 g

Storage and dosing of powdered minor ingredients such as flavourings, colours and similar items is a critical part of many confectionery and baking lines. As well as high-accuracy dosing, the hermetic storage of such ingredients is vital to preserve product quality and reduce wastage. A dedicated system designed to handle challenging micro-ingredients reduces wastage and increases the production efficiency.


<h2>Hermetic storage and accurate metering of powdered micro-ingredients</h2>
The Trimix System from Cepi is a completely modular and expandable system for the storage and accurate dosing of powdered micro-ingredients.

Suitable for all ingredients, the Trimix system is particularly suited to challenging ingredients such as milk powder, cocoa powder and salt. Trimix has been engineered so that no product is trapped in the storage units or dosing station, eliminating waste.

For powders, dust and leakage are avoided thanks to the Trimix suction system, which operates directly from the sacks. As well as fully automated suction dosing, Trimix has the option of manual operation via a floor or table scale system where powder control is not required.

Modular design means that units can be supplied to meet your exact product and space requirements.

Advanced features include built-in homogenizer, bar code scanning and tracking, and ultra-fast discharge option increases the number of batches.

Microdosing system for bakery industry

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

Fill up to 24,000 vials per hour with pharmaceutical powders or liquids under aseptic conditions.


<h2>High speed sterile vial filling with 100% integrated check-weighing.</h2>
The Romaco Macofar MicroMaxX is an indexed motion microdosing machine for the dosing of sterile powders into glass vials in sterile environment, by means of vacuum/pressure system and subsequent closure with rubber stoppers. The aseptic injectable vial filling machine offers mechanical speeds ranging from 6,000 to 24,000 vials per hour.  The vacuum filling, first in class dosing system available on the market, highly reliable and largely validated, can be complemented with peristaltic pumps to perform liquid filling.

The machine can be configured with in-line, high speed, TARE/GROSS 100% check-weighing system, representing the perfect machine to process the most valuable and critical products of the customer. MicroMaxX is conceived to comply with the latest GMP regulations, thus meeting market’s highest quality requirements and Romaco customers’ needs.

High-speed aseptic injectable vial filling machine

<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

Fill sterile pharmaceutical powders into vials under aseptic conditions with a speed of up to 18,000 vials per hour.


<h2>Leading Microdosing machine for the sterile filling of powder into vials</h2>
The Romaco Macofar Micro 6, 9 and 18 are machines suitable for filling sterile pharmaceutical powders into vials under aseptic conditions. The Micro range of intermittent motion machines offers mechanical speeds ranging from 9,000 to 18,000 vials per hour. The powders are filled using a vacuum / pressure system. The cylindrical glass vials are then sealed with a rubber stopper.

Microdosing machine for sterile powders is designed for cGMP compliance and thanks to its balcony design, they are considered to be a leading powder micro-dosing machine.

Microdosing machine for sterile powders