Recipharm & Syntegon upgrade GKF 2500 from one to three tablet stations
The market for tablets filled into capsules has been growing for years. This dosage form is proving particularly advantageous due to its controlled dissolution behavior. Moreover, the capsules are easier for patients to accept. The long-standing business partners Recipharm and Syntegon are breaking new ground for this type of production past upgrading a GKF 2500 capsule filling motorcar from one to three tablet stations – and are celebrating a successful premiere.
Tablets filled into capsules are enjoying increasing popularity in the pharmaceutical market. One of the reasons is that encapsulated tablets are much easier for patients to have. Some tablets could not be administered without the protective capsule because of their ambitious consequence on the mucous membranes of the mouth and breadbasket. Pharmaceutical manufacturers avert this problem past filling the coated tablets into a capsule that dissolves in a controlled way subsequently overcoming gastric juice resistance.
However, this trend confronts pharmaceutical producers too as contract manufacturers with new challenges regarding their equipment. Recipharm was no exception when a client approached the contract manufacturer with a very special request. He wanted Recipharm to fill three differently colored tablets of the same size into one sheathing. "The customer project was and still is a novelty in many respects," explains André Trommer, supervisor mechanic at Recipharm. "We take never before filled several tablets into one sheathing. We did not all the same have the necessary machine in our product facility. So we had to come up with a solution that was technically feasible and has a small footprint."
Long-standing partnership breaking new basis
Recipharm (formerly Espoused Medical) and Syntegon (formerly Bosch Packaging Engineering) are onetime acquaintances and wait dorsum on a long business relationship. At its German locations in Zwickau, Monheim, and Wasserburg, the contract manufacturer produces pharmaceutical products for customers worldwide. Syntegon's GKF machines have been in use here for over thirty years. The concluding one was put into operation at the beginning of 2017. Information technology is a GKF 2500 ASB 100% capsule filling machine in the high-performance segment. The machine is equipped with an automatic trouble-shooting system (ASB) and a capsule weighing motorcar (KKE).
With an output of up to 150,000 capsules an hour, the capsule filling motorcar is suitable for powders, micro-dosing, pellets, and liquids. The exact filling quantity is pressed into a capsule via a dosing disk earlier the integrated checkweigher examines each individual sheathing and sorts out whatever that are incorrectly filled. Due to the machine'due south modular design, products with changing parameters can exist quickly candy and precisely dosed. Recipharm has and then far used the GKF 2500 primarily for pellets and powder products. Moreover, Recipharm fills pellets in combination with a tablet using the existing tablet station and the retrofitted pellet station. The GKF 2500 is also suitable for filling tablets and micro-tablets into capsules – simply up to now only with one tablet station.
All proficient things come in threes
When the new customer contacted Recipharm, engineering specialist Jens Muhsold before long realized that he wanted to give the existing GKF 2500 a try. "I have been working with the GKF platform for over a quarter of a century and still have great conviction in the quality and reliability of the machine and its manufacturer." Recipharm decided to realize the demanding projection together with Syntegon and to upgrade the capsule filling car for the new customer projection.
"We needed a creative solution which, in add-on to the filling itself, besides took into account the express space available on the car," says Muhsold. "This projection depends on the successful upgrade. Hence, the pressure on both u.s.a. and our colleagues at Syntegon was very high. Flexibility was a priority throughout the entire project. And the Syntegon team truly demonstrated its flexibility."
Dual control for quality assurance
Although the three tablets contain different agile ingredients, they are identical in size and weight, said Syntegon. The simply divergence is their different colored coatings. Therefore, information technology is all the more important to ensure that just 1 of each tablet ends up in each sheathing. The existing tablet station had already proven its worth in do due to its reliable dosing process. Mechanical filling via a dosing disk makes sure that only the desired number of tablets reach the capsule base. In the unlikely outcome of a tablet getting stuck in the chute, the integrated gravimetric weighing cell automatically problems an alarm.
To be entirely on the prophylactic side, the tablets' identical weight requires a further command phase. Since the space within the capsule filling car was already used up past the three tablet stations, the 2d footstep had to be transferred. The color inspection of the tablets is therefore not carried out on the GKF but on the downstream blister machine (by the fashion, an older TLT 3060 from Bosch) past means of color recognition. "We likewise looked for the best possible solution for this step together – and found information technology by efficiently using an existing technology," says Trommer.
Teamwork for flexible problem solving
In the meantime, extensive tests have confirmed the reliable and high quality of the dispensed capsules. In the hereafter, Recipharm volition be able to process capsule sizes 0 and 00 with different tablet sizes on each of the three tablet stations of the GKF 2500 sheathing filling auto. What sounds simple in retrospect required a lot of courage and delivery from both sides within a short time. "The task was tricky because there were no parameters for comparison with previous projects. However, the tests proceeded without whatsoever problems. I am very satisfied with the technical implementation and the commitment of the unabridged service squad," says Muhsold.
The upgrade of the GKF 2500 from one to three tablet stations was a showtime for both Recipharm and Syntegon. Notwithstanding, the project partners completed the conversion in around iii weeks, during which time three Syntegon service technicians were on duty at the Zwickau plant. In this style, a specific customer inquiry turned into a challenging project with significant futurity potential. Recipharm tin can now fill various tablets into capsules, and Syntegon can offer the right equipment for a growing market tendency.
Source: https://packagingsouthasia.com/application/recipharm/
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