IMAgination from IMA
At Achema 2003 the IMA Group has a series of new machines and complete lines for the pharmaceutical industry. There will be equipment from all of IMA's division involved in the pharmaceutical industry. These include the solid dose division, comprising the previous IMA capsules and tablets business line, Kilian and GS, which offers examples such as the new IMA Ghibli 50, a flexible fluid bed processing equipment, in which three different product containers can be fitted: top spray, bottom spray and tangential spray. This allows different technical solutions to be applied, according to the product and to the process to be performed.
The Zanasi Lab 16 is an intermittent motion capsule filling machine, reaching a production speed of 16,000 capsules/hour. The machine can run with a minimum quantity of products and is the ideal solution for r&d application: a tamping pin and a dosator powder dosing system can be fitted in the same machine, as well as liquid, pellets and tablets dosing unit.
The Imatic 200 is a continuous motion capsule filling machine, ensuring maximum reliability and dosing precision even at the high speed of 200,000 capsules/hour. The machine has been specially designed for minimising non-productive times, eg size change, maintenance and cleaning, and the number of parts needed to be dismantled has been reduced. Also, thanks to complete isolation between the production area and the mechanical area, the machine can be fitted with a completely automatic CIP system.
Also on show, the Impressa 130, an intermittent motion capsule filling machine, with production speed of up to 130,000 capsules/hour. The machine is equipped with the new tamping pins powder dosing system, placed above the capsule transport system in the centre of the machine. The unit is extremely flexible, guaranteeing high dosing precision and allowing a separate control of powder weight and compression. The movement between the parts in contact with powder is reduced to a minimum, avoiding contamination of the powder with metal particles. The new tablet press machine Comprima 600 will be on display, too. Introduced on the market in 1995, this series has been very successful thanks to its principle of operation and technology, which provide numerous advantages over traditional compression systems. The 600 reaches a production speed of 600,000 tablets/hour.
There are also two different models of the new series of tablet press machines, the Kilian Synthesis 300 and 700. This is a complete range of machines, from low to high production capacity, designed for easy operation and cleaning. All components have been designed with smooth surfaces and can be easily cleaned. The die table can be taken out without removing the punches, while the force feeder and the tablet discharge are hinged and can be swung out for easy access and cleaning.
Since the mechanical and the compression areas are completely separated and sealed off, there is no risk of product penetration into the lower compartment of the machine: this means no risks of cross contamination, less maintenance operations and 100% 'black spot' free tablets. The very well proven hydraulic overload system makes sure that punches don't break in the event of overload. The Synthesis 300 and 700 reach respectively a production speed of 225,000 and 1,020,000 tablets/hour.
Besides these two machines the new economical E150 Plus tablet press machine will be on show, ensuring high reliability, low servicing costs, long life, machine conversion and a high output combined with excellent tablet quality. The press compartment is easily accessible for changing the tooling. All machine settings can be adjusted centrally by handwheels, provided with graduated scales, while the machine is running. The machine can reach a production speed of 225,500 tablets/hour.
Finally on show, the new solid wall pan GS 300 Evolution, featuring complete isolation of the processing area, including automatic product feeding and discharge, to satisfy containment requirements. The machine is suitable for processing high potent products.
Blister packaging
The IMA Blister Division, together with Win.Pack and the Indian subsidiary Precision Gears, offers a range of blister machines, from low to super high speed - up to 1,200 blister/minute). At Achema there will be some of the latest innovations in blister packaging.
The C80-A81, a pacesetter in IMA's range of blister machines, will be on show. It is a medium speed blister line with integrated cartoner characterised by a superior performance and flexibility, capable of processing up to 400 blisters/minute and 250 cartons/minute. The C80/A81 has gained acceptance in the market very quickly because, unlike the majority of the existing blister lines on the market, the production speed remains high even when producing wide blisters. The C80-A81 is a leading machine worldwide in the medium-speed range also due to its total concept, which is continuous running, thanks to its integrated cartoner and its positive transport of the blister from the blister machine to the cartoner.
Also on show, the new blister packing machine Win.Pack TR200. It is an economical two row blister machine, especially designed for small to medium production runs, also suitable for contract packers, even though its concepts are those of a high-scale production machine. Its main features are balcony construction, completely accessible, according to GMP norms, very economical size parts with a wide range of possible blister dimensions, complete changeover in 15 minutes and the ability to use of all kinds of material (PP monoblister, Alu/Alu blisters, PVC, PVDC, Aclar, PET). The TR200, which reaches a production speed of up to 320 blisters/minute, and will be exhibited in line with the FLEXA cartoner.
Precision Gears, IMA's subsidiary in India, has widened its range of packaging machines with the new blister packing machine Clinipack. Based on the concept of TR100 and TR102, it is a very compact, economical and flexible blister machine, especially suitable for clinical trials and small production runs. The main features of Clinipack are: compact and simple structure fitted with castors – balcony construction, completely accessible, according to GMP standards, stainless steel cladded, intermittent motion, quick and easy changeover without tools, that can work with all pack-aging materials (Aclar, Alu/Alu, Coc, Ecolean, Triplex, PET, PP, PVC, PVDC, PVC+PFC). Clinipack can work both blisters and trays and reaches a production speed of 30 cycles/minute for PVC and 30 cycles/minute for Alu-Alu.
Sterile filling
There will be a complete processing line composed of a Libra Hydra linear washing machine, a Libra Blue Galaxy sterilisation tunnel and a Sterifill F200 FAST, the new high speed in-line filling and stoppering machine for aseptic environments
The Libra linear washing machines of the Hydra series are the result of years of research and experience dedicated to the decontamination of containers for injectable use. Hydra machines have been designed according to GMP recommendations, therefore satisfying the highest quality standards requested by pharmaceutical industries. They are available in a wide range for the treating of all vials used for the pharmaceutical industry with vial speeds up to 34,000 pieces/hour. Hydra machines can be also used for the washing of plastic containers and, upon request, for oval or elliptic containers. The unloading is available onto trays or with connection to rotary tables or to depyrogenation tunnels by means of IMA's special off-set unloading system (first in first out).
Blue Galaxy is a VHP sterilisation tunnel designed to be inserted in a production line that requires continuous depyrogenation by means of dry heat. Precise construction of the chambers, in particular the hot chamber, guarantees perfect distribution and penetration of heat by means of a flow of hot air treated with HEPA filters, which strikes the bottles with vertical laminar motion. Class M3.5 air as per Federal Standard 209/e is guaranteed along the entire path. The heat treatment can be set according to the container to be treated, and guarantees a reduction of endotoxins greater than 3 log. All instrumentation can be fit with devices for easy adjustment and calibration. All process parameters can be set and recorded according to the container to be treated. Technical specifications and technological characteristics guarantee stability of set temperatures in time and space. All of this, plus precise design and construction, make the tunnel ap-propriate for a request for FDA approval. Finally, IMA Sterifill F200 FAST, the new high speed in-line filling & and stoppering machine for aseptic environments suitable for filling liquid solutions into cylindrical vials and for insertion of rubber stoppers. A very compact and narrow machine base allows access to the working parts from one machine side only.
Cartoning
The IMA Cartoning division will exhibit for the first time, Easy the new compact intermittent horizontal cartoner (the small cartoner for the largest carton size) for low speed and large sizes applications for pharmaceutical and cosmetic products. The machine has rapid changeover, ergonomic, sturdy and compact design with easy access, and no maintenance.
Also on show will be two models from the range of Flexa horizontal cartoners for pharmaceutical and cosmetic products. Available both in continuous and in intermittent version the fastest model can reach up to 200 cartons per minute. The Flexa is user friendly thanks to its ergonomical design and fast changeover and features touch screen machine status monitoring system, easy access to size data and parameters and has option compliance to 21CFR Part 11. Servo driven applications makes Flexa cartoners adaptable to pack a wide range of products in a safe operational sequence at optimal speed. The cartoners will be exhibited in line with the Win.Pack TR200 blister packing machine and the Prima tray packing machine manufactured by Farmores, a company represented by IMA.
To complete the wide range of machines exhibited by the IMA Group, there will be a new model from the End of Line Division, which offers a complete range of end-of-line machines (wrapping, bundling, case packing and palletising machines.
On show, the IMA/BFB CP38 new high speed side loading casepacking machine specifically designed to handle loose or bundled cartons. The cantilever design of its structure ensures complete accessibility and easy cleaning. Great importance has been given to the ergonomic position of all its components. All the parts of the machine can be reached from the operator's side. The extremely low positioning of the horizontal case magazine guarantees long autonomy. Servo technology (the CP38 is entirely driven by servo-motors) allows the machine to achieve an output up to 30 cases per minute with smooth product handling.
Hall 3.0 Stands L2/N21