Packaging is a critical process in the pharmaceutical industry, where different grades of products are packed into appropriate packaging material. It is the collection of packaging material, techniques, and quality standards that aims to protect the product, ensure its efficacy, and implement quality.
There are three categories of packaging in the pharmaceutical industry, which differ in the way the packaging material comes in contact with the product. The three categories include primary, secondary, and tertiary.
Secondary packaging is the type that forms the second layer of the packaging material. It is a packaged unit of multiple individual primary packaged products in a group form for handling, storage, and transportation.
Secondary packaging is also used for marketing purposes for the pharmaceutical brand and to communicate drug usage and information to users. One of many secondary packaging types also includes cartons, and the machine used to form cartons is called Cartoner.
What are Cartoners?
Cartoners are carton package machines that pack products in cartons. They take un-folded cartons, give them the required packaging shape, and insert the product in them. After insertion, the pack carton is closed, sealed, and discharged from the outfeed. Depending on the machine design, multiple packages can be inserted into the cartons.
The cartoner relies on mechanical frames, shafts, and parts to give cardboard the required carton dimensions. The primary packaged product insertion also relies on mechanical parts to move from the feed section until inserted into the cardboard packaging. However, the movement of these mechanical frames & structures is controlled through a centralized controller and automation components.
Since every product has its specific & approved carton specification, the machine manufacturer is responsible to incorporate it in its design. These requirements along with others are communicated to the manufacturers during the initial phases of discussion.
What are the Cartoners types used in the pharma industry?
Common types of cartoners used in the pharma industry include Vertical and Horizontal.
Vertical Cartoners
In vertical cartoners, the products are loaded from the top, and hence, they are also known as top-loaded. The product is then picked and placed into the cartons.
In this type, the machine takes flat-sized cartons, and after giving them appropriate physical dimensions, its bottom flaps are closed, while the top flap remains open for inserting product into it. After product loading, the top flaps are closed and sealed.
Vertical cartoners are suitable for products that require strict orientation conditions and cannot be laid flat. They require less space for installation and are composed of complex machine components and parts. They are capable of operating at higher speeds than other types.
Horizontal Cartoners
Horizontal cartoners are types in which products enter sideways or horizontally into the cartons. The product and cartons travel horizontally side by side on two separate routes. The carton is erected horizontally, and one side is closed, while the other remains open. The product horizontally enters the cartons at the filling station or point through appropriate mechanical or pneumatically controlled components.
Horizontal cartoners are used for products that require horizontal laying, such as blister packs and sachets. They require more space than other types and have less operational speed.
Automatic and Semi-Automatic Cartoners in the pharma industry
There are two modes of operation for cartoners: semi-automatic and automatic. These two differ in how the product enters the cartons.
Semi-Automatic Cartoners
In semi-automatic cartoners, operators manually insert the product into cartons. After insertion, the machine processes the product further.
In this type, the machine operation is intermittent. It stops for product placement and executes further steps after placing the product into the cartons. Due to its design and intermittent operation, it is slow in speed.
Due to their simpler design and less automation, semi-automatic machines are cheaper than fully automatic machines. However, they are labor intensive and require more operators for efficient operation. They are preferred for situations where less investment is available and low production volumes.
Automatic Cartoners
In automatic cartoners, the entire cartoning process is automatically controlled and requires no human intervention. The product transfer to the filling station and insertion into the cartons is also handled automatically, without operator involvement. They can operate at high speeds and use complex automation components to accomplish their operation.
They are suitable for high production volumes due to high speed and are expensive as compared to semi-automatic cartoner. However, they are less labour-intensive.
There are two automatic modes of operation: continuous and intermittent.
· In continuous mode, the conveyor carries cartons and does not stop, and the product is inserted into the cartons while in operation. They are suitable for high-speed lines that do not require special assistance during insertion.
· In intermittent mode, the conveyor carrying cartons stops for the product insertion. After filling, the conveyor carrying (filled) cartons moves to the next stage for further processing. They are used for products that require special handling during filling and due to the delicacy of their nature.
Key features for pharma-specific Cartoners
Caroners are not only used in the pharmaceutical industry; they are also used in other manufacturing industries, such as food and beverages. The difference for pharma applications is the safety, quality, and efficacy of final packed products, which require unique pharma-specific features.
Some of them are described below.
Automate controls
The entire operation of cartoner can be controlled through automation technology, where HMI interfaces with the humans to know their requirements. The PLC takes input from various sensors and use programming algorithms to process the action in accordance with user requirements & specifictions
Servo-driven positioning
To successfully perform the cartoning action, it requires a high degree of synchronization between different sections, such as carton erection, production insertion, and sealing. These processes must be performed relative to one another, i.e., one after another. This level of precision is performed using servo drivers.
The servo driver drives servo motors that can rotate with precise control of position and speed. The motor’s force is converted into mechanical movement through appropriate coupling, shafts, and other components. The servo driver is controlled through a centralized controller, such as a PLC, to control motor operation with respect to machine position, speed,, and movement with other stations of the machine.
For the cartoning process, the servo helps to
· Repeatability of all processes
· Protecting the product from damage by controlling the mechanical stress
· High Quality standards
· Fast and accurate cartoning process
· Less wastage, by preventing damage to products and cartons
Automated leaflet feeding systems.
Leaflets are small pieces of paper that are inserted into secondary packaging of pharmaceutical products. The cartoner machine also includes the leaflet feeding system, which inserts the leaflets into cartons after the product is inserted.
It is a dedicated section of the cartoner that automatically feeds. It utilizes a combination of pneumatic, mechanical, and electronic systems for precise leaflet insertion into the cartons. It is activated precisely at the point when the carton is erected and is aligned with the carton movement.
Some designs enable automatic folding of leaflets to fit the size of cartons, while others require leaflet feeding in a folding form.
The Vision Inspection System
The vision inspection system ensures that the packaged carton is free from any physical defect and contains its necessary contents, such as leaflets and products. Vision inspection ensures quality and regulatory compliance.
There are two methods to implement a vision system: camera and sensor.
· In camera-based systems, an image is taken of the actual packaging process at each stage, such as leaflet and product insertion. The captured image is compared with the threshold image (satisfactory image). The particular carton is accepted if it matches the threshold image, indicating satisfactory operation. If there is a difference between the captured image and the threshold image, it is marked as erratic and is ejected
· In a sensor-based system, a proximity sensor senses the content of a carton as it advances through the packaging process. The sensor detects the presence of satisfactory cartons and is transmitted to the main controller, which also marks it as safe in its system. If any component is absent, the sensor will sense it, which is also transmitted to the main controller for appropriate action.
The output of the vision inspection system is connected to a flapper that divides the accept and reject channels. If any carton is rejected, the flapper is activated and the carton is guided into the rejection side. Otherwise, it goes into the accept side.
Advantages of using Cartoners
Let’s look at some advantages of using cartoners in pharma packaging.
· Cartoners help with flexibility in the packaging process by enabling easy changeover between different products, catering to production and market requirements.
· The cartoner can be operated with minimum human intervention, which helps prevent human error and reduces the chances of contamination.
· Less human involvement also enables a safety culture at packaging lines.
· Using automatic cartoners enables pharma manufacturers to increase productivity in a given time.
· It enables detecting any issues with the packed cartons, such as missing products and leaflets, which is vital for patient safety and prevents market recalls.
· Automation components like PLC and HMI enable a complete record of each packed or rejected carton.
· The cartoner can be integrated with various data recording technologies, in accordance with regulatory compliance
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