Efficient Project Management for Pharmaceuticals

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Pharmaceutical industry hygiene standards demand complete sterility of primary packaging. Bosch ensured the entire filling and capping process, situated in unbroken Class A clean room conditions, would stand up to the most stringent inspections. It is essential to prevent any contamination of sterilised and depyrogenated bottles, especially in a line operating at through-puts of up to 300 containers per minute.

To maintain sterilisation, all components of the line must be fully integrated and products must move quickly through the production process.

Effective project management can save money and help bring products to market faster. (Picture: GEA)

NCPC’s packaging chain starts with the Bosch RRU cleaning machine, which balances robust, residue-free cleaning with gentle handling. Following an ultra-sonic bath, the bottles are transferred to a rotary system via plastic grippers, specifically designed to minimise the contact area for a better cleaning result.

The containers then pass through the HQL sterilisation tunnel that uses the vertical hot air laminar flow principle to sterilise and depyrogenate the vials at 320 °C. Once the drying and sterilisation is completed, the bottles are conveyed quickly through the cooling section, and are eventually transferred for filling.

Compact Fillers – Made in Germany

The centrepiece of the line is the AFG 3000 compact filling machine. It was assembled at Bosch’s Crailsheim facility in Germany. The filler provides fast and gentle conveyance and accurate, dust-free dosing. It operates using the vacuum pressure principle. Due to this unique dosing method, the vials are filled very precisely: Initially, the powder is transported to a dosing chamber by vacuum.

Then it is dosed into the container with sterile compressed air. After each dosage, the dosing chamber is cleaned with additional sterile compressed air. To minimise the risk of particles, rubber stoppers are fed horizontally from a supply hopper and pressed in tightly with a horizontally operating vacuum wheel.

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