C96A96BLISTER PACKAGING MACHINE WITH INTEGRATED CARTONER

C96A96

WHEN PHARMACEUTICAL PRODUCTION NEEDS ARE:

Lower production costs per blister by increasing •

production batch sizes

Products with large sales volumes•

Faster introduction of new products to the market •

Limits in production space•

Larger blisters•

Alu-Alu blisters•

Blister standardising •

IMA SAFE’s C96A96 IS THE ANSWER

Th e C96-A96 super high speed blister Line responds to these needs

and represents the highest level of mechanical achievement in

Blister Packaging.

Its conception comes from the hard work done by a dedicated

team of IMA Safe Engineers as well as the experience

gained from having delivered more than 2000 medium and

high-speed machines worldwide.

Th e C96-A96 was designed with the most technologically advanced

concepts while guaranteeing high reliability and effi ciency within

the entire packaging process.

The C96A96 is a high speed blister machine designed specifically for those customers who need to run uninterrupted large batches with fast and frequent changeovers and from to lanes during production shifts.

C96A96

Th e IMA Safe C96-A96 blister line has been designed for the highest outputs and effi ciency that

can be reached in the world: 1300 blisters/minute and 450 cartons/minute. Th e line concept is

based on continuous motion. Continuous motion off ers signifi cant advantages with both material

forming as well as the handling of products with diff erent shapes and sizes by way of simple and

effi cient feeding systems.

Th e integrated high-speed A96 cartoner, designed specifi cally to be used with the C96, uses

positive blister transport and is an evolution of the fi rst system which was designed by IMA in

1976. Integrated monobloc machines with positive blister transport achieve the highest possible

machine effi ciencies and outputs. Th e A96 features fast and easy changeover and cleaning which

helps reduce downtimes to a minimum.

Th e C96-A96 can also include optional features which further eliminates the need for operators so

that non stop production can be obtained. Th e CF600 is a system to automatically load cartons to

the A96 with a robotic arm; leafl ets can be taken off a reel and do not need to be hand feed into

a “GUK” by an operator; an automatic loading and splicing system can be also be installed so that

the C96-A96 will be in constant production.

The C-A monobloc machine continues the IMA blister philosophy that was first applied, in , to the C-A.Designed with balcony construction and for easy changeover, the C-A handles all materials, incorporates a PC as an operator interface and controller, and has an integrated connection between the blister machine and the cartoner.

1 2 3

C96A96

FORMING

PVC, PVC/PVDC, ALU, ACLAR®, COC, PP:

all materials can be handled resulting in

high quality blisters with excellent barrier

properties and top performance rates.

Material reel diameters can range from 400

to 1000 mm. which further reduces operator

interventions.

Th e PVC reel holder has been specifi cally

designed to avoid stops in machine

production.

1 2 3 4

FEEDING

IMA Safe feeding systems are designed as the result of over 40 years of experience in the blister

packaging industry and obtain a fi lling effi ciency of 99.9%. Th ese systems have been designed

according to GMP principles which facilitate cleaning and reduce changeover times to a minimum.

Fixed feeding positions assure the inter-changeability of parts and therefore help reduce overall

expenditures. Extremely delicate and complex shaped products are handled with ease while

assuring elevated production output.

A specifi c department within IMA Safe is dedicated to product feeding solutions and includes

several GMP Test Rooms for product feeding under controlled environmental conditions.

Solutions are found which are based upon each unique product.

All IMA Safe feeding systems feature:

No operator assistance•

Wide feeding bowls for maximum feeding performance•

Continuous web motion•

Higher camera effi ciency due to continuous fi lm motion granting greater •

product stability in the pocket

Easy integration of multiple product feeding systems.•

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4 5 6 7

SEALING

IMA Safe’s continuous roller sealing system

evenly distributes heat and pressure without

damaging the product or the forming

material itself. A single contact or sealing

line eliminates residual heat which allows

blisters to remain fl at. IMA’s specifi c pyramid

grid creates a continuous seal around the

entire pocket edge with uniformity in the

laminating layers.

CARTON MAGAZINE

Th e elongated carton magazine on the A96

is fi tted with a moving belt that facilitates

carton transport towards its withdrawal.

Th e system is also designed to avoid dust

falling down on the mechanical parts of the

machine.

CUTTING AND POSITIVE TRANSPORT

Th e cutting station uses quick change levers

for fast and easy changeovers. Th e positive

blister transport system also rejects faulty

blisters or stacks proper blisters toward the

integrated cartoner.

CODING AND PERFORATION

High precision coding and perforation

systems are used in combination with an

accurate web driving system to assure proper

positioning and alignment. Th ese systems

also have individual disconnection levers for

quick and easy changeovers.

LEAFLET TRANSPORT

Leafl et transport from the folding unit up to the

introduction is completely visible and accessible.

Th e leafl et is pre-inserted into the carton through

a double mobile blade for high effi ciency. Th is

system is exceptional eff ective when dealing with

more diffi cult product presentations such as of

alu blisters, PP monoblisters and very big leafl ets

5 7 8

3 4 5

87

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SEPARATION BARRIER

Th is area has been specifi cally developed to

create a simple barrier of separation between

the blister and cartoning area while still allowing

maximum accessibility for cleaning. Th e

separation and the specifi c design of the system

guarantees the minimum interaction between

the two areas which helps to eliminate the

possibilities of contamination.

6

SPEED AND FLEXIBILITY

Th e C96-A96 can run to up to 1300 blisters/

minute Blister cards, up to 98 mm long, can

be produced on 3 lanes while blister cards

with dimenions up to 145 mm long can

be run on 2. Changing production from 2

to 3 lanes, or vice versa, can be quickly and

easily performed. Th e integrated, balcony

design, A96 cartoner can produce up to

450 cartons/minute and can handle the

largest range of carton sizes that the market

has to off er (carton sizes: width 35 mm

up to 95 mm, length 70 mm up to 150 mm and

height 12 mm up to 90 mm)

SPECIFIC FEATURES OF THE C96A96 WHICH DISTINGUISH IT FROM COMPETITIVE SYSTEMS.

OVERALL EQUIPMENT EFFECTIVENESS O.E.E.

Th e pharmaceutical industry is continuously

striving to increase overall production effi ciency

levels in order to justify capital expenditure.

Th e C96-A96 is the ideal solution to obtain

this objective when high and medium level

production speeds are needed. Th e monobloc,

or integrated blister and cartoning machine,

signifi cantly reduces the number of product

rejects, the consumption and cost of packaging

materials and consequently the amount of time

and energy which is need to produce a specifi c

batch size. Complete format size changes

can be completed within 90 minutes which

dramatically reduces machine downtime.

Th e entire machine has been designed to avoid

any possible operator mistakes.

Competitive machines with similar production

capacities cannot obtain the high O.E.E. of the

C96-A96.

SIZE CHANGEOVER AND CLEANINGComputer guided changeover with toolless

quick pin release change parts can be

performed in record time. A complete size

changeover including blister size, product

feeding system and new carton size, can be

completed in less than 90 minutes.

Cleaning, which can be a sensitive issue, is

quickly and easily done due to the simple

and ergonomic design of the forming,

feeding, sealing, cutting, transfer, stacking

and cartoning groups.

Th e whole line has been built in compliance

with GMP. Its balcony construction, smooth

surfaces, oil-free belt drives and no hidden

corners guarantee easy cleaning with no risk

of cross-contamination. Th e critical units

like feeding, cutting and carton magazine

are designed in such a way to avoid any dust

accumulation during the whole production

process.

C96A96

USER FRIENDLY DESIGN

With the ergonomic balcony design of

the C96-A96 monobloc, all components

are highly visible and easy to follow by the

operator. From the forming station to

the stacking station and through to the

cartoner, the entire production process

can be easily monitored throughout the

machine.

CAN-bus connections located in the rear of

the machine drastically reduce cable space,

thus granting easy access for maintenance

operations.

All material handling can be carried out •

from the front of the machine

Easy machine set-up•

Interactive computer interface•

Short cleaning time thanks to specifi c GMP •

design.

OPERATOR INTERFACE

A computer touch screen, with colour

monitor and graphic representation, enables

easy and intuitive management of the

machines production and status. Production

statistics, trouble shooting, including

changeover instructions, maintenance and

manuals can also be obtained through the

HMI. Production data can also be seen in

accordance to the Din 8743 specifi cation.

IMA Safe can also supply the high-resolution

quality control Antares Vision system which

is completely integrated into the single HMI

computer interface. Th e Antares System uses

high performance easy-to-learn, easy-to-use

software and cameras which also allows for

new products to be loaded in its system

without the need for outside assistance.

HIGHTECH SERVOMOTORS

Servomotors are used throughout the

machine and grant intelligent operation and

100% precision. Servomotors are in the blister

area, the connection and the cartoner.

Th is technology has been applied especially

to reduce changeover times and to increase

fl exibility in the use of very diff erent

packaging materials.

ERGONOMIC BALCONY DESIGN OF THE C96A96 MONOBLOC

AN EXCELLENT INVESTMENT

Because of the high effi ciency of the forming, driving

and sealing systems, the C96 blister machine works

with all materials pvc, pvc/pvdc, alu-alu, Aclar®, coc,

polypropylene, reaching the highest standards in

each case. Th e forming system of the C96 is based on

functional small moulds working at very high speeds.

Th is assures excellent temperature control, uniform

and controlled distribution of the formed web on the

pocket profi le, and easy, very rapid size changeover.

Th e cutting station with quick-change properties

is positioned so that material fragments cannot get

into the unit. Th e discharge system separates empty

and part-fi lled blisters. Fail-safe: self-control logics

are available for rejection implemented. Th e blister

cutter works in such away as to simplify the transfer

of the blister to the cartoner. Th e cartoner receives

the blisters by means of an integrated blister stacker

and positive blister transport system that guarantees

maximum security coupled with a very high running

effi ciency.

C96A96

INTEGRATED CARTONER

A continuous motion cartoner was exclusively designed to

work in tandem with the C blister machine.

The innovative features of the machine make it the ultimate

solution in carton packaging:

Complete balcony construction, meaning that jams can be ◾

easily removed

Carton transport through tooth fitted belts keep ◾

the cartons in the correct position during the whole

transport process

Chain free to avoid cleaning issues ◾

The largest carton magazine in this range of machines ◾

(up to metres long)

Quick changeover in less than minutes ◾

The pushers operate from the rear. The machine is

entirely accessible from the front.

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SPARE PARTS

Th e use of original spare parts is essential to

guaranteeing perfect machine working order

and providing full production effi ciency.

Spare parts can be ordered from IMA directly

or via the MyIMA e-commerce system and

shipped to you within 24-36 hours.

IMA UNDERSTANDS THE NEED FOR EXCELLENT SERVICE AROUND THE WORLD

Present in over countries ◾

branches providing sales and service ◾

More than representing agencies ◾

technicians from Italy supplying worldwide service ◾

technicians from local subsidiaries and agencies ◾

after sales supervisors ◾

SALES AND SERVICES

IMA SAFE provides prompt and eff ective

technical assistance which covers the entire

life cycle of its equipment. Th is assistance

is provided by a dedicated team of experts

able to meet our client’s needs on a day to

day basis. A customer oriented after sales

service staff is what distinguishes IMA from

the other manufacturers.

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TRAINING

IMA SAFE organizes specific staff training

(certificate issued at the end of the course)

in order to give the customer the possibility

to achieve the maximum efficiency in the

shortest time. The courses not only cover the

functioning of the machine but also include

practical aspects and daily operations such

as size changeover, routine and special

maintenance, troubleshooting, cleaning,

quality control and other functions.

ADVANTAGES

Efficiency increase ◾

Shorter change over time ◾

Faster error analysis ◾

Preventive maintenance ◾

VALIDATION

In the pharmaceutical industry, the validation of a production

process implies the provision of documented evidence to

demonstrate that the process is capable of producing a consistent

product which conforms to predetermined specifi cations and

quality criteria.

Upon request IMA will provide customers with a comprehensive

package of documentation to support on-site validation procedures

in the most simple and fast way. Diff erent packages are available

according to individual requirements.

C96A96

SIZE PARTS

IMA size parts are fully tested before being sent to the customer,

which ensures that production can start immediately.

Originally manufactured size parts allow IMA machines to work at

their highest production effi ciency.

Size parts are designed with a combination of detailed technical

knowledge and practical know-how.

Detailed experience with all types ◾

of packaging materials

Detailed knowledge of the customer’s ◾

particular machine configuration

Design and drawing systems based ◾

on the technical parameters of each

machine model.

Integrated Antares Vision System•

Diff erent forming and lidding material reel-holding •

possibilities

PVC hole perforating attachment for child-proof•

Pinhole detection on aluminium forming material•

Protection system for product/operator with laminar fl ow •

concept utilising over or under-pressure techniques

Special air fl ow systems in contact with the product•

Automatic tablet loading unit from fl oor level•

System to feed multiple products simultaneously •

in the same blister

Lidding material fl exographic/laser printing•

Print registration on lidding and cold forming material•

Lidding material preheating•

Grid sealing on both blister sides (for cold-formed blisters only)•

Blister and carton coding (embossing, ink-jet, laser, etc.)•

Dust, forming and sealing fume extraction with centralized •

exhaust for operator’s safety

Computerized spare parts management•

Computerized line machine statistical data collection•

Closed circuit cooling system•

Leafl et insertion (all commercial systems available)•

Booklet insertion•

Possibility of separation between blister machine and cartoner•

Hot melt glue system for various kinds of carton closures•

Trolley for easy disassembling/assembling of complete size parts•

Trolley for material transport•

21 CFR Part 11 compliance•

Track & Trace solutions.•

SIGNIFICANT OPTIONS OFFERED ON THE C96A96:

C96A96 TECHNICAL DATA

Th e dimensions are indicative and can vary depending

on the optional groups chosen and machine lay out

PRODUCTION OUTPUT

3 rows Up to 1300 blisters/min

2 rows Up to 850 blisters/min

cartons Up to 450 cartons/min

BLISTER DIMENSIONS CARTON DIMENSIONS

Width 30-90 mm 35-95 mm

Length 65-145 mm 70-150 mm

Depth 3-12 mm 12-90 mm

MACHINE DIMENSIONS MACHINE WEIGHT

Length 13500 mm

18000 KgWidth 1500 mm

Height 2060 mm

Forming materials

Aluminium laminate, PP, PVC, PVC/PVCD, PVC/

ACLAR®, PET, COC and others

Lidding materials

Alu-Hard, Alu-Soft, Alu/Paper,

Alu/Polyester, PP and others

www.ima-pharma.com

May

201

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96-A

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EN

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1BG

1201

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IMA S.p.A.

IMA SAFE division

Via I Maggio 14/16 - 40064 Ozzano dell’Emilia (Bologna) - Italy

Tel. +39 051 6514111 - Fax +39 051 6514743

mktg.packaging@ima.it - www.ima.it

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