HRG Longyan assists BFS production enterprises in achieving seamless integration from front-of-line production to end-of-line packaging, ensuring continuous production
Publishdate：2024-10-18 Views：144
The solution proposed by Ha Gong Long Yan for the continuous production of BFS production lines has helped enterprises achieve seamless integration from front-end production to back-end packaging.
The new version of EU GMP Appendix 1 not only puts forward higher requirements for the production of sterile drugs, but also recommends the application of some new technologies. For example, BFS aseptic filling technology is becoming a new direction for aseptic product packaging due to its high degree of automation, high level of aseptic assurance, minimal insoluble particles, diverse packaging, high production efficiency, low production costs, and compliance with energy-saving and consumption reduction requirements.
However, in actual production, the front-end production and back-end packaging of BFS production lines still rely on manual operations, making it difficult to achieve true continuous production, which is also one of the reasons for the high labor costs of enterprises.
Ha Gong Long Yan has proposed a solution for the continuous production of BFS production lines, achieving seamless integration from front-end production to back-end packaging.
01 Ha Gong Long Yan Online/Offline Cache System,
Realize continuous production and effectively reduce the number of operators
Due to the process characteristics of the BFS production line, the front-end production process needs to maintain uninterrupted production for at least 72 hours, resulting in a high dependence on manual multi batch operations in the back-end packaging process, especially the manual collection and release after BFS cutting, which not only increases labor costs but also seriously restricts production efficiency. Therefore, achieving continuous production is a sharp sword for pharmaceutical companies to reduce costs and increase efficiency.
Ha Gong Long Yan has innovatively developed an online caching system, which includes cutting-edge technologies such as pallet transfer AGV, automatic palletizing robot, collaborative robot, 3D vision inspection, material conveying system, traceability system, and intelligent control. It replaces traditional manual collection, loading, unloading, and manual loading and unloading processes, and can flexibly connect multiple filling machines, effectively reducing operators and saving space resources. This change enables seamless automation of the entire chain from blowing and sealing, material caching system, automatic light inspection and leak detection, to the final packaging area, ensuring continuous production.
Specifically, the online caching system is used for the front-end filling machine to maintain production. When the back-end packaging is not in production or there is a malfunction in the back-end packaging, the system is installed after BFS punching. The unpacking (palletizing) robot uses 3D vision to unpack the empty turntable and place it in the loading position. The collaborative robot then accurately grabs the materials and places them in the turnover tray. Once the turntable is filled, it will be automatically transported to the inspection station for quantity detection. Then, the unpacking (palletizing) robot will palletize the turnover tray filled with materials. After palletizing is completed, the AGV (automatic guided vehicle) will transport the fully loaded pallets to the designated temporary storage area to prepare for the subsequent packaging process.
When the packaging plan is initiated, the AGV (Automated Guided Vehicle) is precisely scheduled again to transport the pallets directly from the temporary storage area to the packaging site. Subsequently, through advanced 3D visual recognition technology, the system is able to accurately identify and sequentially dismantle pallets, and feed materials into the packaging production line. At the same time, the palletizing robot carries out palletizing and delivery, forming a cyclic material flow system.
The entire process is continuous and efficient, not only reducing errors caused by manual operations, but also greatly improving the stability and efficiency of the BFS production line, with a stable speed of up to 150 versions per minute! It can process up to 9000 products per hour. Moreover, the system can customize the cache capacity according to customers' production needs (such as different requirements for single dose and multi dose), achieving flexible adjustment of the cache system's cache time between 1 and 5 hours.
For workshops with limited space, HAGONG Longyan has thoughtfully designed an offline caching system. In this mode, the previous and next week's turntable work can be manually assisted by robots for loading and unloading. When the backend equipment fails, the robot automatically loads the disk. When the backend resumes production, the robot automatically unloads the disk. This not only retains the efficiency and precision brought by automation, but also takes into account the flexibility of the actual environment.
02 Whole line online control, precise selection
Targeted development of light inspection and leak detection machines to safeguard continuous production
In continuous production, the lamp inspection and leak detection process is a key factor that restricts the degree of continuity. The speed is not up to par, resulting in poor efficiency; The detection rate and accuracy are not up to standard, resulting in uncontrollable drug quality.
To achieve continuous production, HAGONG Longyan has partnered with well-known domestic brands in the field of lamp inspection to develop highly stable and accurate lamp inspection and leak detection machines to ensure the quality of drug production. This device is capable of accurately detecting 2 μ m micropores, achieving a 100% detection rate, and fully meeting the production capacity requirements of up to 150 versions/minute (750 pieces/minute) in the previous production process.
For products with poor fluidity such as sodium hyaluronate, the equipment has been carefully optimized, integrating fast flipping function to ensure that the liquid in the bottle cap can be redistributed to the bottle body, effectively solving the detection problem. Meanwhile, the equipped double-sided detection mechanism further enhances the detection accuracy.
The back-end packaging of BFS production line involves many equipment such as online light inspection machine, leak detection machine, caching system, labeling machine, pillow packing machine, box packing machine, wrapping machine, automatic packing machine, robot palletizing system, etc. Without a "core brain", it is difficult to achieve efficient collaboration of these processes.
Ha Gong Long Yan has developed a targeted online control system for the BFS back-end packaging production line, which can seamlessly integrate various equipment links, achieve real-time data transmission and intelligent scheduling. To ensure the stability and efficient operation of the production line, HAGONG Longyan not only strictly screens and considers the selection, electrical configuration, and brand of each piece of equipment, but also configures an intelligent monitoring system to provide data collection and analysis services, which can timely detect and handle potential problems.
03 Customized Design
Accurately meet the diverse needs of pharmaceutical companies
The design of non-standard products greatly tests the skills and experience of project solution designers. Harbin Gonglong has been deeply involved in the packaging field for 15 years and is well versed in the diversity of pharmaceutical companies' needs. Its customized development is always based on comprehensive considerations of product characteristics, spatial layout planning, detail processing, and other dimensions.
Taking a pharmaceutical company in Suzhou as an example, the "soft, irregular, and light" characteristics of its eye drops have increased the difficulty of upgrading the automation of the BFS production line. The soft bottle body is prone to deformation due to compression during transportation, resulting in product quantities deviating from the preset arrangement, which poses a challenge to the accuracy of counting and arrangement; Due to its unique design features
The solution proposed by Ha Gong Long Yan for the continuous production of BFS production lines has helped enterprises achieve seamless integration from front-end production to back-end packaging.
The new version of EU GMP Appendix 1 not only puts forward higher requirements for the production of sterile drugs, but also recommends the application of some new technologies. For example, BFS aseptic filling technology is becoming a new direction for aseptic product packaging due to its high degree of automation, high level of aseptic assurance, minimal insoluble particles, diverse packaging, high production efficiency, low production costs, and compliance with energy-saving and consumption reduction requirements.
However, in actual production, the front-end production and back-end packaging of BFS production lines still rely on manual operations, making it difficult to achieve true continuous production, which is also one of the reasons for the high labor costs of enterprises.
Ha Gong Long Yan has proposed a solution for the continuous production of BFS production lines, achieving seamless integration from front-end production to back-end packaging.
01 Ha Gong Long Yan Online/Offline Cache System,
Realize continuous production and effectively reduce the number of operators
Due to the process characteristics of the BFS production line, the front-end production process needs to maintain uninterrupted production for at least 72 hours, resulting in a high dependence on manual multi batch operations in the back-end packaging process, especially the manual collection and release after BFS cutting, which not only increases labor costs but also seriously restricts production efficiency. Therefore, achieving continuous production is a sharp sword for pharmaceutical companies to reduce costs and increase efficiency.
Ha Gong Long Yan has innovatively developed an online caching system, which includes cutting-edge technologies such as pallet transfer AGV, automatic palletizing robot, collaborative robot, 3D vision inspection, material conveying system, traceability system, and intelligent control. It replaces traditional manual collection, loading, unloading, and manual loading and unloading processes, and can flexibly connect multiple filling machines, effectively reducing operators and saving space resources. This change enables seamless automation of the entire chain from blowing and sealing, material caching system, automatic light inspection and leak detection, to the final packaging area, ensuring continuous production.
Specifically, the online caching system is used for the front-end filling machine to maintain production. When the back-end packaging is not in production or there is a malfunction in the back-end packaging, the system is installed after BFS punching. The unpacking (palletizing) robot uses 3D vision to unpack the empty turntable and place it in the loading position. The collaborative robot then accurately grabs the materials and places them in the turnover tray. Once the turntable is filled, it will be automatically transported to the inspection station for quantity detection. Then, the unpacking (palletizing) robot will palletize the turnover tray filled with materials. After palletizing is completed, the AGV (automatic guided vehicle) will transport the fully loaded pallets to the designated temporary storage area to prepare for the subsequent packaging process.
When the packaging plan is initiated, the AGV (Automated Guided Vehicle) is precisely scheduled again to transport the pallets directly from the temporary storage area to the packaging site. Subsequently, through advanced 3D visual recognition technology, the system is able to accurately identify and sequentially dismantle pallets, and feed materials into the packaging production line. At the same time, the palletizing robot carries out palletizing and delivery, forming a cyclic material flow system.
The entire process is continuous and efficient, not only reducing errors caused by manual operations, but also greatly improving the stability and efficiency of the BFS production line, with a stable speed of up to 150 versions per minute! It can process up to 9000 products per hour. Moreover, the system can customize the cache capacity according to customers' production needs (such as different requirements for single dose and multi dose), achieving flexible adjustment of the cache system's cache time between 1 and 5 hours.
For workshops with limited space, HAGONG Longyan has thoughtfully designed an offline caching system. In this mode, the previous and next week's turntable work can be manually assisted by robots for loading and unloading. When the backend equipment fails, the robot automatically loads the disk. When the backend resumes production, the robot automatically unloads the disk. This not only retains the efficiency and precision brought by automation, but also takes into account the flexibility of the actual environment.
02 Whole line online control, precise selection
Targeted development of light inspection and leak detection machines to safeguard continuous production
In continuous production, the lamp inspection and leak detection process is a key factor that restricts the degree of continuity. The speed is not up to par, resulting in poor efficiency; The detection rate and accuracy are not up to standard, resulting in uncontrollable drug quality.
To achieve continuous production, HAGONG Longyan has partnered with well-known domestic brands in the field of lamp inspection to develop highly stable and accurate lamp inspection and leak detection machines to ensure the quality of drug production. This device is capable of accurately detecting 2 μ m micropores, achieving a 100% detection rate, and fully meeting the production capacity requirements of up to 150 versions/minute (750 pieces/minute) in the previous production process.
For products with poor fluidity such as sodium hyaluronate, the equipment has been carefully optimized, integrating fast flipping function to ensure that the liquid in the bottle cap can be redistributed to the bottle body, effectively solving the detection problem. Meanwhile, the equipped double-sided detection mechanism further enhances the detection accuracy.
The back-end packaging of BFS production line involves many equipment such as online light inspection machine, leak detection machine, caching system, labeling machine, pillow packing machine, box packing machine, wrapping machine, automatic packing machine, robot palletizing system, etc. Without a "core brain", it is difficult to achieve efficient collaboration of these processes.
Ha Gong Long Yan has developed a targeted online control system for the BFS back-end packaging production line, which can seamlessly integrate various equipment links, achieve real-time data transmission and intelligent scheduling. To ensure the stability and efficient operation of the production line, HAGONG Longyan not only strictly screens and considers the selection, electrical configuration, and brand of each piece of equipment, but also configures an intelligent monitoring system to provide data collection and analysis services, which can timely detect and handle potential problems.
03 Customized Design
Accurately meet the diverse needs of pharmaceutical companies
The design of non-standard products greatly tests the skills and experience of project solution designers. Harbin Gonglong has been deeply involved in the packaging field for 15 years and is well versed in the diversity of pharmaceutical companies' needs. Its customized development is always based on comprehensive considerations of product characteristics, spatial layout planning, detail processing, and other dimensions.
Taking a pharmaceutical company in Suzhou as an example, the "soft, irregular, and light" characteristics of its eye drops have increased the difficulty of upgrading the automation of the BFS production line. The soft bottle body is prone to deformation due to compression during transportation, resulting in product quantities deviating from the preset arrangement, which poses a challenge to the accuracy of counting and arrangement; Due to its unique design features
