A completely rounded piece of work
New thermoforming, filling and sealing machine keeps the line running smoothly

Process reliability and dependable operation of the packaging machines are crucial factors in the pharmaceutical production process. Problems are often introduced when components from different suppliers are linked together in the packaging line. A new thermoforming, filling and sealing machine has been developed to ensure that the line continues to run without problems.

Today’s packaging machines must be easy to operate. Customers need short changeover times, and the machines have to be accessible from all sides. However, when components from different manufacturers are integrated into a packaging line, problems can occur that impair a smooth product flow. For example, the intermittend mode of operation of thermoforming, sealing and punching stations linked with Schubert picker lines has prevented a smooth flow of packaging foil and formed trays. The F44 pick and place robots were not able to deliver peak performance.

The newly developed TLM-T800 uses traveling and repeating forming and sealing/punching units. The units move back and forth, allowing a continuous flow of packaging foil. This enhances the performance of the picker line. Continuous flow avoids acceleration and deceleration which can cause the products to shift on the tray. This in turn degrades the reliability of F44 placement operations. As is the case with other models in the TLM series, the TLM-T800 is accessible from all sides. The drives and bearings for the forming and sealing/punching subassemblies are located above the foil feeding plane. This makes the machine easier to clean, which can be very helpful in applications that require washdown. The product conveyor is located in the center of the TLM-T800. Similar to most Schubert picker systems, the TLM-T800 features a dual-line design. A thermoforming, filling and sealing/punching line is located along each side of the product conveyor. The conveyor and the foil transport system use a patented counter flow design. A single-line version, the TLM-T400, is also available. All process motion is servo-controlled and can be digitally adjusted.
Continuous foil feed
The FFS process consists of a series of steps. First the foil is unrolled and fed into the machine. A chain gripper on each side feeds the semi-finished products into the foil transport system. The foil is transported continuously in the direction of flow. Contact heaters in the heating station bring the material up to the right temperature, and then thermoforming takes place. A high-efficiency system cools the forming tools and enables fast cycle times. The tools are coded so that the correct production program can be loaded after changeover. This prevents the tools from operating with the wrong program, and it also avoids collisions and damage. The F44 robot fills the cavities which have been formed. A F44 unit consists of two picker arms which have four degrees of freedom each. A vision system enables the robot to detect the position of the product. The picker arm takes the product and places it into the tray. The sealing foil is sealed to the base foil in the sealing/punching station. The packaging is punched on one and the same station. The packaging is then removed and moved on for further handling.
Automatic foil change
Continuous foil feed is not the only outstanding feature of the TLM-T800. Foil reels can be changed automatically. If the foil on one reel has been used up, foil is automatically fed from the second reel. The first foil reel can then be replaced while the foil from the second reel is running through the thermoforming process. The design team is also looking at automatic reel change for the sealing foil, and there are plans to use print marks to control feeding of pre-printed sealing foil.
Thermoforming can be performed with compressed air and/or vacuum in the forming station with or without plug
assist support. The forming station is suitable for both positive and negative thermoforming. The plan is to support all
packaging materials that are commonly used in the pharmaceutical industry (foil thickness: 0.6 mm, foil width: 400 mm, feed 300 mm, max. drawing depth: 80 mm). It is important to remember that not all polymers are equally suitable for thermoforming, sealing and punching. The application spectrum includes soft and hard packaging.
Reducing sealing
Ultrasound is used for sealing and punching. A generator creates electrical energy, and a converter changes this energy into mechanical vibration at a frequency of 20 kHz. A booster can be added to increase the amplitude of the vibrations. The vibrations are fed to the sonotrode, which hammers the anvil. The foils to be processed are positioned between the sonotrode and the anvil. Ultrasonic technology minimizes thermal stress and sealing time. The process can also create a tight seal on contaminated surfaces. The energy introduced by the ultrasonic generator for the sealing process can be compared with reference values. This makes it possible to check that every seal is tight and reject faulty items, providing validation of the sealing process. The sealing station also acts as the punching station. The ultrasonic sealing/punching tool separates the plastic packaging unit from the foil strip. Ultrasonic punching requires less force than conventional shear punching, so the punching presses do not have to be as elaborate. The cutting edge of the punching tool uses ultrasound to melt the material, resulting in less wear on the tool and the station. The combination sealing/punching station uses less space compared to systems that have separate stations.
The new thermoforming, filling and sealing machine offers a number of very significant advantages. Servo drives provide reproducible motion, which is reflected in higher quality thermoforming results. Efficient thermoforming technology reduces material consumption. Material and product sizes can be changed quickly, and this saves time. Continuous motion of the foil transport chain reduces wear on the chain links. Ultrasonic technology minimizes sealing time and extends service life.
However, standardized design is probably the biggest advantage of the TLM-T800 thermoforming, filling and sealing machine, because it enables the user to simplify the production process.