At breakneck speed
New high-speed machine for pharmaceutical packaging

Uhlmann Pac-Systeme’s highlight at interpack is the fastest thermoformer in the world. This new high-speed machine marks the beginning of a new era in thermoformers. Operating at breakneck speed and with high precision, the machine produces up to 1300 blisters/minute that are then transferred to downstream machines. But there’s more to be seen on the Uhlmann stand at interpack, as this article reveals.

When developing new machines, it is Uhlmann’s strategy to work closely with the customer. Some packaging tasks appear at first glance to be insoluble. Ultimately, however, an answer is always found: 7000 packaging machines operating throughout the world—and no two are the same—speak for themselves.

The new B 1880 thermoformer, based on a tried and tested high-performance model and further developed to meet specific customer needs, meets every aspect of pharmaceutically compliant, cost-effective, hygienic and reliable high-speed production, and also satisfies the latest requirements for industrial safety and ergonomics. Using state-of-the-art material technology, with a machine frame made from cast mineral material and stainless steel, and incorporating innovative design details such as the ingeniously simple sliding and closing mechanism of the doors, the B 1880 offers added protection for operating personnel, easily accessible operating controls and simplified operation. The protective doors are scratch resistant, non-splintering and easy to clean.
Thanks to ToolControl, an identification system for the correct selection of tools and format parts, the B 1880 achieves good changeover times. The twin reel support for the forming film allows preparation for film roll changes to be carried out without halting production. The machine easily processes all common types of film, and sophisticated components enhance process reliability: an example of the latter is the pressure pads that optimize sealing of the tools against forming air during the forming process. Air and heat are drawn off inside the machine frame through a central outlet, ensuring a clean-room atmosphere. Not least, the machine dimensions have been reduced and the noise level during production lowered.
A high-speed line live in action
Visitors to interpack can see the B 1880 thermoformer in action at the heart of a high-speed line comprising a tablet press from Fette, a tablet lift from Thomas Büchele, the B 1880 thermoformer, a C 2404 cartoner, a checkweigher from OCS and an S 3040 stretch-banding machine, all directly linked for synchronized production meeting the highest quality standards. This line features speed as well as the smooth integration of machines and components from other manufacturers in an efficient packaging line. The primary SCADA system controls the interaction of each component of the packaging line.
At the beginning of the line, the tablet press produces round, convex tablets. The tablet lift transports them to FlexTab, a high-speed feeding system from Uhlmann. The B 1880 thermoformer then gets a chance to show off its speed by running at 1260 blisters/minute. The blister packs then pass to the C 2404 cartoner, which packs them into cartons in stacks of three. Output is 420 cartons/minute, or seven cartons/second. The checkweigher compares the actual weight of the filled cartons with the specified value.
The final process step is based on another recent development from Uhlmann: the S 3040 stretch-banding machine for banded and shrink-wrapped bundles. Last year, Uhlmann extended its range of end-of-line packaging machines, adding three new stretch-banding machines with different throughputs. Compactness is the outstanding feature of the new S series: the basic machines have a footprint of just 1 m x 1 m, thus meeting the demand of the pharmaceutical industry for space-saving machines. The S series machines incorporate all the basic components of larger stretch-banding machines, ensuring that they are reliable, efficient and easy to operate.
Uhlmann’s understanding of packaging does not stop at linking separate machines to create an integrated packaging line. It also includes maximum safety and reliability through process monitoring. Various monitoring components from Uhlmann’s subsidiary VisioTec feature on the high-speed line at interpack, including two VisioChrom HR cameras. These detect the smallest of errors, impurities and otherwise imperceptible defects in the blister. One camera is mounted upstream of the sealing process, the other downstream. A high-resolution VisioRead camera also ensures that the information printed on the blister matches the required data. Next, an in-line printer that forms part of the VisioPrint laser printing system applies graphics to the covering foil. Finally, two VisioScan systems scan the surface of the film and foil. The VisioScan systems can detect material flaws as small as 10 µm, invisible to the naked eye.
Variable: the line for hospital packs
A second Uhlmann line shows the production and packaging of weekly blister packs. It comprises a B 1240 thermoformer, a SimTap feeder and an S 3015 stretch-banding machine. 21 capsules for seven days are packaged in a large blister, arranged with a capsule each for mornings, midday and evenings. This type of packaging is particularly interesting for hospitals or clinics such as rehabilitation centers. The size of the blisters and the need to link to the stretch-bander limits the output of this line to 40 blisters/minute, though the B 1240 thermoformer has a maximum output of 350 blisters/minute.
The blisters are transferred directly from the thermoformer onto the feed conveyor of the S 3015 stretch-banding machine. This stacks the blisters and wraps them into eight compact bundles per minute, each containing five blisters. Other special features of this line include a VisioChrom camera system that checks the products after feeding and in-line printing of the lid foil, a variable-length fill section, variable drawing depths and a wide choice of product types.
More than 1300 of these classic Uhlmann machines are in operation throughout the world. They work with the same precision in both industrialized and developing countries, efficiently packaging
a wide variety of products, from tablets to syringes. By taking existing machine designs and adding a practically infinite permutation of feed systems and accessories, a customized solution is available for nearly every product and application.
Two into one for wallets
The third line at interpack 2005 is a
joint effort between Uhlmann and Harro Höfliger. It comprises Uhlmann’s high-performance thermoformer UPS 1030 ET and a wallet machine from Harro Höfliger.
Tablet blisters are produced and immediately integrated into wallet packs. Wallets are the ideal packaging form for consumer-orientated products and are becoming increasingly popular with patients as they are easy to handle and offer additional benefits. Analysis aids, scales and tables can easily be integrated, as can self-diagnosis applications or sample packs, different booklets or guidance systems for ease of compliance.
The demonstration line at interpack uses the tablet blisters produced by the UPS 1030 ET to feed the wallet machine. 240 wallets/minute leave the line folded, printed, glued and marked with identification codes.
The Uhlmann Customer Support & Services division is also on the interpack stand. Various support services for packaging machines will be demonstrated, including the new NetCare maintenance service generator, which calculates and displays the next service date for each machine, based on the machine type and production data. Also featured on the stand is an “anti-ageing” programme for elderly packaging machines. And last but not least, also on display is the finishing touch for every packaging line: in-line monitoring systems from VisioTec, solution for maximum safety combined with maximum output.