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Most countries have largely recovered from the Covid-19 pandemic. In 2020, things were different. During a filling project for PCR diagnostics in 2020, time was of the essence – to complete the project faster than originally planned. Two rotary machines, one new and one existing machine, which was upgraded to state-of-the-art standards, were to go into operation on time.
The motto of the project was, “the sooner, the better”. However, even under time constraints, machine quality remained the most critical criterion. After all, the well-being of many people depends on proper production processes.
The project was based on an existing custom-designed system for filling diagnostic liquid into cartridges and closing with a film. Now, the customer wanted the exact same system, processes, and functions as the system built in 2008, while adhering to the latest technical and safety standards. Simultaneously, they sought to update their existing system to the same standards.
It can be safely assumed that the customer, a renowned company for active pharmaceutical ingredients, as well as diagnostic tests and ingredients, was satisfied with the first edition of the machine, if it is to serve as a template for the second, new system, 12 years later. At the same time, 12 years of daily operation inevitably led to insights how to improve the system. Feedback from the customer and the Optima service department, which maintained the existing system over the years, was directly incorporated into the new design.
The improvements included, in particular the drive, the conversion to current safety standards and technologies, as well as various additional material upgrades. The new installation and modifications to the existing system would unavoidably interrupt ongoing production. Consequently, the project team had to make this project phase as short as possible. The intended timeframe for the entire project: 10 months – instead of the minimum 12 months Optima had originally calculated.
Reducing the time line by two months requires intensive cooperation from everyone – internally and externally. A strategic and trusting partnership, like the one that has been established with this customer for years, is very beneficial. Pushing the limits regarding the project timeline also means that many, but not all, customer requests can be implemented within the required time frame.
Rational and quick decision-making by management, speedy design reviews and the contribution of everyone working with the machines on a daily basis, characterized the close cooperation with the customer.
At Optima, particularly close coordination was required between the design and technical purchasing departments – to clarify which parts would be available and when, or whether there was a useful alternative. At this point, the supply chains were already under significant strain and demand on pharmaceutical suppliers high. Meanwhile, Optima service technicians provided valuable input on how to improve the machine’s durability and precision.
As part of the updates to improve format changes for the five different container sizes, updates were installed.
Part of the updates to the first machine version was a new container magazine. This means the systems can now be operated without interruption.
Five different, custom-designed cartridge formats are processed on the system. A revolving magazine serves as container storage, into which entire container “towers” can be inserted manually. From this enlarged magazine, the containers are stacked into a transport star wheel. In the updated machine versions, the revolving magazine and the entire system are equipped with a servo drive, which allows more time for stacking into the transport star wheel leading to an overall increase in performance. In addition, operators can now add containers during operation, which greatly increases system efficiency.
The rotary machine has two filling stations with rotary piston pumps, each filling 50 Percent of the diagnostic liquid. Dividing the filling process into two stations provides a higher performance than filling 100 Percent of the product at a single station. The filling station is followed by the first closing station, where aluminum film is fed from the roll and decontaminated inline using UV radiation. Its width corresponds exactly to the container dimensions therefore, 100 Percent of the film is used without creating any waste. The punched-out film is placed on the container by pick-and-place and fixed at four points. With the fixed film on the cartridges, they are then transported to the second closing station, to heat seal the film. A laminar airflow covers the revolving magazine, filling and closing station completely.
All (repeatedly) inspected cartridges are now transferred to an inkjet printer with a linear transport system. The film is imprinted and checked for accuracy by a camera system. A continuous scale checks the cartridges for their final gross weight. Once these inspection points are passed, the products from the two diagnostic machines are combined on a newly installed conveyor and transported to the automated secondary packaging equipment.
Material improvements were made to the star wheel and shafts. Parts previously made partially of aluminum are now designed in stainless steel. These format parts are not only more durable, but offer greater long-term precision, for example during heat sealing.
Pre-sealing at four points and then final heat sealing. No waste: 100 Percent of the film is used.
After pre-closing, there is enough time to complete the final heat-sealing with a high output.
Finally, in the midst of the pandemic, the installation phase of the new system took place, including the rebuild of the existing system with the new format parts. Exact timing was the key. To reduce machine downtime as much as possible, Optima once again closely coordinated with all departments. Optima sent two teams of specialists to the customer site. Setting up a new system and converting an existing system on site are two different things, each having their own individual challenges. The intensive planning, and carefully examination of the conditions on site, paid off. Both the installation and conversion time windows were met – as well as the entire project timeline of 10 months. Both systems operate according to the customer’s requirements. The maximum output of both systems is identical: 1,500 objects per hour.
After completing this project, the customer placed another order for a diagnostic machine with Optima – positive customer feedback! This time it is a significantly larger system and another custom designed machine to meet specific customer requirements.
