Custom Blow / Fill / Seal Machinery

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Swing Arm Deflasher

Our Swing Arm Deflasher is designed to be incorporated downstream of our B/F/S machine, typically outside of the cleanroom. This unit is designed to deflash cards of 0.5 to 20mL containers after moving along a conveyor. A swing arm motion extracts the finished containers utilizing a pick and place device, placing them down onto a product exit conveyor. At that point they exit in an orientated manner, being available for your further inspection checks, process, or packaging.

Scrap is controlled and moves to an exit scrap conveyor and then integrates to your removal system. The control system is within its structure and totally independent of the B/F/S machine. The punch and die tooling is hydraulically actuated and secondary motions are pneumatically driven. Power, hydraulic, and pneumatic energy is sourced from the B/F/S machine.

LVP Bottle Deflasher

The LVP* Bottle Deflasher is also incorporated downstream of our B/F/S machine, typically outside of the cleanroom. This unit is designed to deflash 50 to 1000mL LVP bottles produced from P.P. resin material. Bottle from our B/F/S machine transfer along a conveyor to the punch and die tooling zone. The design can perform top and bottom deflashing including hanger designs.  Transfer grips move the finished containers to an exit conveyor. At that point they are available for your further inspection checks, process, or packaging. 

A good example would be those finished bottles transiting into our Cap Welder machine. Scrap is controlled and moves to an exit scrap conveyor and then integrates to your removal system. The control system is within its structure and semi-independent of the B/F/S machine with some handshaking logic involved. The punch and die tooling is hydraulically actuated and secondary motions are pneumatically driven.  Power, hydraulic, and pneumatic energy is sourced from the B/F/S machine.

*Large Volume Parenteral

Take-Out Deflasher

Our Take-Out Deflasher assembly can be integrated with the Mold Carriage of most of our B/F/S machines.  This unit is designed to remove the top flash from LDPE resin containers in the 0.5 to 1000mL range that have just extracted from the mold set. This action occurs within the normal cycle of the B/F/S machine.  The lower area acts as clamp jaws to hold the containers during cycle movements and during the deflashing sequence.

The finished containers are placed onto an exit conveyor to move out of the cleanroom. At that point they are available for your further inspection checks, process, or packaging.

Scrap is controlled and moves down a chute to an exit scrap conveyor and then integrates to your removal system out of the cleanroom. The punch and die tooling is hydraulically actuated.  Hydraulic and sensor electrical energy is sourced from the B/F/S machine.

Filer Integrity Test System

A filter Integrity Test System is available.  In-situ integrity testing of aseptic system filters can be performed on the air and product filters installed on the machine.  The test circuits are set up automatically for each product filter through an auxiliary panel provided on the machine.  All integrity test attachments are directly incorporated into the filtration circuit.  This highly sensitive instrument is designed for use in all locations including the laboratory or inside the process suite or cleanroom.  This test instrument is fully compliant with 21CFR part 11 for electronic and data record storage. 

Data Management

Secure collection, logging, and reporting of critical operating data can be enabled.  A software program is provided to permit the assignment of a password to each employee.  When the employee logs in an ID record is made with date and time.  Changes showing both the previous and new value entries are recorded on a storage media located on the HMI.

A two-component package is available to enhance the environmental process conditions within the extrusion zone of the ASEP-TECH® machine.  HEPA filtered air is supplied to an enclosed area encompassing the parison head and mold transport area of the ASEP-TECH® machine.   Airflow to this area is monitored with a flow sensor and alarmed to ensure consistent operation.  Control of this “zone of protection” reduces effects due to potential changes in the machine room environment. 

A secondary stainless steel collection shroud encloses the parison head and is coupled to an exhaust system with an external blower to be mounted outside the cleanroom within 30’ (9 meters) of the ASEP-TECH® machine.

This combination system helps ensure that typical non-viable particle counts in this area will meet US FDA Class 10,000 under dynamic conditions.

Parison Shrouding System Parison Shrouding System

Environmental Monitoring

An airborne particle counter can be provided for continuous environmental monitoring of the nozzle shroud.  Count programming, capturing and recording is available through an electronic interface. The data can be sent directly to the temperature/process controller or linked to a customer-supplied system.

Transport/Installation Cart

A maintenance cart on casters with a height-adjustable lifting platform and safety brake is available for transport/installation of custom tooling.  Fixtures specifically designed to assist with the removal and installation of the mold(s), fill nozzle assembly and parison head are included, when this cart option is selected. 

Slitter/Singulator

Fully automatic or manual-load slitter/singulators can be provided, custom designed to enable separation of containers after the deflashing station.  The designs permit complete separation of each “pack” to produce different combinations (singles, 2-packs, 3-packs, etc.).   Alternatively, blade spacing can be set to produce an initial (or partial) separation at the parting lines of the connected containers while keeping the original “pack” partially attached to enable downstream material handling (labeling and leak detection). 

This is very important when Polypropylene is the resin of choice, since the characteristics of this resin can make separation of individual containers difficult.  The slitter helps minimize this difficulty by initiating the separation without human intervention.

Blades are double edged to permit easy, rapid changeover to minimize down-time.  Included is a spare blade module, mounted in a convenient storage location.

SLITTER/SINGULATOR  SLITTER/SINGULATOR

Viable Particulate Microbial Sampling Tube

The viable particulate monitoring tube is a device which is affixed to the Blow/Fill/Seal machine above the Class 100 nozzle shroud.  The viable particulate monitoring tube is partially inserted into the Class 100 environment so an adequate and representative sample of air can be withdrawn from the Class 100 environment.  The sweeping elbow design of the viable monitoring tube ensures a smooth transition between the Class 100 environment and the customer supplied sampling device.  The tube is fabricated from 316L stainless steel with a 1-inch Tri-Clover connection on the downstream side, to be adapted to the customer's sampling device.