Solution Of Pharmaceutical Filling Line

I. Introduction:

In general, the pharmaceutical filling line is a linkage production line made up of several sets of equipment with different functions to satisfy production or processing of one product. It is an electromechanical appliance to reduce human power, optimize working procedures and improve production efficiency in deed. The operating procedures are different for different materials. The operating procedures below are for reference.

1. Containers are sent to rinser for flushing in a turn-over state after cleaning in the bottle washing machine;

2. Drying or sterilization is performed for flushed containers depending on different product requirements (for different industries);

3. Handled containers are transferred to underneath of filling nozzle for quantitative filling. (Different filling method is adopted for different materials, for example, direct flow filling for conventional liquid materials, pressure filling for paste materials, screw metering for powders, cup metering for granular materials and negative pressure filling for gas-bearing materials.)

4. Capping is performed by the capping machine after filling of materials. (vacuum capping, direct capping or pressure capping can be selected based on different caps.)

5. Generally capped products are pasted with labels.

6. The identification device is finally used to print manufacturing date or batch number of products.

7. Product output.

II. Detailed introduction:

1. Washing, drying, filling and sealing line of ampoules

The linkage washing, drying, filling and capping line of ampoules is designed especially for liquid injections. The production line consists of ultrasonic bottle washing machine, hot air circulating sterilizing tunnel oven, ampoule filling and sealing machine. The vertical ultrasonic bottle washing machine can complete preliminary ultrasonic washing of bottles, cleaning of outer wall of bottles and three times of air washing and rinsing for inner of bottles. The hot air circulating sterilizing tunnel oven can dry, sterilize and remove pyrogen from washed bottles. The ampoule filling and sealing machine can complete pre-filling of nitrogen, medicine liquid filling, post-filling of nitrogen, drawing and sealing functions. This linkage line is equipped with advanced instruments at home and abroad, which can detect, print and store process parameters on line. At the same time, an isolation protection system is configured on the filling and sealing machine, which meets requirements of GMP of the latest version. This machine is a large electromechanical integrated intelligent equipment for pharmaceutical industries with stable performance, beautiful outlook and reliable operations. Besides, this machine is configured as per customers' technological requirements, meeting production demands of different bottle specifications and production capacities. Meanwhile, each machine can also be used alone.

2. Washing, drying, filling, stoppering and capping line of vials

The linkage washing, drying, filling, stoppering and capping line of vials mainly consists of automatic ultrasonic bottle washing machine, hot air circulating sterilizing tunnel oven, filling and stoppering machine and capping machine. Each machine can be used alone or linked in production. When in linkage mode, water spraying, ultrasonic cleaning, overturning of track by 180º, flushing of inner and outer walls of bottles, air flushing, preheating, drying and sterilization, pyrogen removing, cooling, (pre-filling of nitrogen), filling, (post-filling of nitrogen), stoppers unscrambling, stopper pressing, cap unscrambling, capping and other procedures can be conducted. It is mainly used for production of vial injections and freeze-dried powder injections in pharmaceutical factories.

3. Powder filling line:

The powder filling line mainly consists of automatic vial unscrambling machine, automatic bottle washing machine, hot air circulating sterilizing tunnel oven, automatic powder filling and capping machine and labeling machine, which is generally used for filling of all kinds of powders, such as ganoderma lucidum powder, penicillin powder, cephalosporin powder, food powder and chemical pesticide powder. The whole line is designed and manufactured as per latest GMP standard. The powder filling machine employs servo motor to control high-precision screw for feeding without powder leaking, to guarantee high filling precision and beautiful and fixed sealing. The whole process from bottle distributing to labeling and packaging is covered, saving human power and ensuring stable operation. It is an ideal equipment for packaging bottled powders.

4. Intelligent sterile pre-filled syringe filling and sealing line:

The intelligent sterile pre-filled syringe filling and sealing line is characterized by fast production speed, stable performance and no cross pollution. Compared with conventional equipment, it saves half occupied area and reduces costs of environment protection and manpower by over 20%. Coordinated control technology is adopted, realizing automatic film stripping, lining removing, filling, plunger rod inserting, weighing and other operations of per-filled syringes, further improving the production speed. The unmanned operation solves the risk of cross pollution in manual operations. Switchover of complex motion loci and paths can be performed by the intelligent sterile pre-filled syringe filling and sealing line and one set of production system can satisfy requirements of 0.5-20ml specifications. Molds can be changed easily to adapt to specifications of different packaging materials such as Cassette bottle, vial bottle, thus satisfying flexible production requirements and improving equipment stability greatly. It is mainly used for unpackaging, film stripping, filling and plunger rod inserting of disposable syringes in honeycomb paper tray of pharmaceutical factories.

5. BFS machine of plastic bottles:

Three-in-one technology of BFS refers to the automatic process of continuous completion of molding, blowing, filling and sealing of containers on one equipment. It is mainly applied to sterile packaging of plastic containers of 0.3ml~1000ml specifications in pharmaceutical, chemical and food industries. It is applicable to small-volume container, small-volume injection, disposable single-dose eye drops for ophthalmic remedy, multi-dose eye drops which can be repeatedly closed, oral solutions, medical small container with special shapes, inhalation drugs, cosmetics (like hyaluronic acid), large-volume container, large-volume intravenous injections with special caps and integrated hanger, inhalation products of respiratory system, wound cleaning solution and eye lotion/lens care products.

6. Washing, drying, filling and capping linkage line of oral liquid:

The washing, drying, filling and capping linkage line of oral solution is made up of ultrasonic bottle washing machine, hot air circulating sterilizing tunnel oven, filling and capping machine. It is suitable for production of oral solution bottles of 2-25ml specifications and can finish linkage operation of such procedures as water spraying, ultrasonic cleaning, water and air flushing, drying and sterilization, cooling, filling and capping of oral liquid bottles in drug production.

7. Large-volume bottle filling linkage line:

The large-volume bottle filling linkage line is made up of rotary bottle unscrambler, drum-type ultrasonic bottle washing machine, linear filling and stoppering machine, capping machine, etc. This production line is suitable for washing, drying, filling, stoppering and capping of 50-500ml glass and plastic bottles. It can be used in linkage mode or unlinked mode. The equipment of the line feature stable and reliable performance and low noise. Besides, corresponding equipment can be selected based on production capacity or specifications to meet demands. It adopts linear reciprocating tracking filling and electromagnetic vibrating cap feeding. It can be sealed by rolling cap (metal type) or screw cap (plastic cap). It can be connected with front and back production process equipment to form a production line. In addition, a hundred-level laminar flow hood can be configured optionally.

8. Linkage line of Non-PVC soft bag IV infusion:

The linkage line of Non-PVC soft bag IV infusion is mainly used for production of 100-1000ml medicine bag infusions in LVP workshop of pharmaceutical factories. It contains three procedures, i.e. bag making and forming, filling and hot melting and sealing. It can automatically finish the following procedures: film feeding, printing, port unscrambling and pre-heating, film dividing, bag forming, port welding, bag cooling, waste edge removal, bag transfer, bag inspection, liquid filling, nitrogen filling, cap unscrambling, cap welding and sealing, bag discharge, etc. Besides, the whole infusion bag packaging line can be set up through linkage with auxiliary equipment such as port feeding machine, cap feeding machine, soft bag transfer machine, sterilizer, bag loading&unloading machine, leakage inspection machine, light inspection machine, etc.

9. Eye drops filling line:

The eye drops filling line is made up of six main parts, i.e. bottle unscrambling, bottle transfer, sterile air bottle washing, bottle filling, inner stopper pressing, and outer cap screwing. The whole eye drops filling process is finished under 100-grade laminar flow protection and sterile isolation. In addition, each zone is isolated and protected to ensure sterile production of eye drops, conforming to national latest GMP requirements, and this line is also applicable to production of other small-volume plastic bottles.

10. Spray/aerosol filling line:

The spray/aerosol filling line is applicable to filling of syrup, oral liquid tincture, lotion, pesticide, solvent and other liquids into bottles in pharmaceutical, food, pesticide and chemical industries. The whole line can perform automatic bottle unscrambling, air washing, piston filling, cap screwing, aluminum foil sealing, labeling, etc. of bottles. The spray/aerosol filling line has a function of stopping filling when there is no bottle, with reasonable design and compact structure, easy for operation and maintenance and meeting GMP standard.