Servo Base PLC Control Vial Filling With Pick And Place Type Stoppering Machine

Application & Process

The Prism Servo-based PLC control vial filling with pick and place type stoppering machine is designed for accurately and efficiently filling vials with liquid or semi-liquid products in various industries. It is particularly suitable for pharmaceutical, biotechnology, healthcare, cosmetic, and chemical industries where precision, reliability, and sterile filling are critical.

Process:

1. Vial Loading: Empty vials are fed into the machine through a vial loading system, such as an infeed conveyor or a vial unscrambler. The machine’s pick and place system carefully positions the vials in the designated filling area.
2. Filling Operation: The servo-based PLC control system ensures precise control over the filling process. The machine uses diving nozzles or reciprocating nozzles to dispense the liquid product into each vial. The filling volume can be adjusted through the PLC interface, allowing flexibility to handle vials with different fill sizes.
3. Vial Stoppering: After the filling process is complete, the machine’s pick and place system accurately places a rubber stopper on the vial opening. The pick and place mechanism ensures proper alignment and gentle handling to avoid any damage to the vials or stoppers.
4. Capping or Sealing: In some configurations, the machine can also include a capping or sealing station where caps, lids, or aluminum seals are applied to the vials after the stoppering process. This ensures the product remains securely contained and protected from external contaminants.
5. Inspection and Rejection (Optional): In high-quality production environments, an inspection system can be integrated to check the filled vials for any defects or discrepancies. Vials that do not meet the specified criteria can be automatically rejected from the production line.
6. Labeling and Packaging (Optional): Depending on the production requirements, the filled and sealed vials may undergo labeling and be packaged into cartons or trays for further distribution.

Advantages:

• High Precision: The servo-based system offers accurate and consistent filling volumes, reducing product wastage and ensuring uniformity.
• Versatility: The PLC control allows easy adjustments for different vial sizes and filling volumes, making the machine suitable for various products.
• Sterile Filling: The pick and place type stoppering mechanism ensures a clean and sterile filling process, critical for pharmaceutical and healthcare applications.
• Efficient Production: The automation provided by PLC control and pick and place system increases production efficiency, reducing labor costs, and improving throughput.
• Reliable Operation: The combination of servo control and PLC ensures reliable and repeatable performance, minimizing downtime and maintenance needs.

Salient Features

• Design is cGMP - Current Good Manufacturing Practices compliance.
• All Product contact parts AISI 316/316L & non contact parts AISI 304.
• ± 1% Filling accuracy on a single dose.
• Provision for Full and Half Stoppering.
• Provision for inert gas purging – before and after the filling.
• Rejected without stopper vial shall be store in a safe condition.
• Rigid vibration free construction.

Safety Features

• Overload relay protection and emergency stop.
• Machine guard interlocking with process.