packazine
Pharma · Issue 2014
Serum Institute | High-quality vaccines for everyone
Novartis | Customized system for highest flexibility
2 | packazine
Table of contents | Editorial
Table of
contents
10
16
News
Facts & Trends
04
Diabetes | Fighting a global pandemic
Customers & Markets
Pharma
07
Laboratorios Normon | New fluid bed system triples batch sizes
10
Siemens & Co. | Modified thermoforming line for packaging of „Emser pastilles“
13
Serum Institute | Affordable, high-quality vaccines for everyone
16
Excelvision | Keeping an eye on automation
18
Novartis | Bosch supplies flexible filling and packaging line for pharmaceuticals
21
Allergy Labs | Peristaltic pump put to the test
24
Cipla | Flexible solutions for complex formulations
Events
26
Events 2014
Cover
With a fully automated packaging line
Excelvision accelerated production
with help from Bosch.
www.boschpackaging.com [email protected]
packazine | 3
18
Editorial
21
Dear readers,
This year, the focus of all our efforts at Bosch Packaging Technology is on Interpack 2014, the
world’s biggest packaging technology trade fair. Back at the very first Interpack in 1958, the former
companies Hamac Packmaschinen and Hansella-Maschinen (later Hamac-Hansella), Hesser, Höller,
Magrolo-Maschinen (later Makat), Sapal and SIG’s packaging sector
(later SIG pack) from the food and confectionery sector as well as
the pharmaceutical packaging machinery manufacturers Höfliger &
Karg and Strunck presented their machines. These companies today
have become part of the Bosch family, making Bosch Packaging
Technology unite more than 150 years of packaging know-how
Friedbert Klefenz
under one umbrella. We will keep with the tradition of Interpack
President,
participation this year, too, by using the show as a platform to pre-
Bosch Packaging Technology
sent you our latest innovations and proven portfolio on almost
3000 square meters of booth space.
The entire packaging machinery industry is in a time of change, the defining trends of which are still
ever stricter regulations on production hygiene, constantly changing consumer requirements, and
the imperative to cut costs. We at Bosch Packaging Technology are determined not simply to react
to these changes, but to play an active part in shaping them.
As we work to develop our innovations, we always have your needs as a producer in mind. Come to
Interpack and be inspired by the equipment that Bosch can offer, which will give you the flexibility
to react quickly to changes in the marketplace and help you to meet hygiene regulations. Our equipment is designed to support fast changeover times, quick and thorough cleaning, and simple operation – all of which increases the efficiency of your production process. In addition, we are there to
provide you with advice and tailor the best solution for your specific requirements: That might
involve an upgrade to existing machinery, partial automation of your production line or it could mean
a complete, seamlessly integrated system, that covers not just the production of bars, say, but also
primary, secondary, and end-of-line packaging. We are also there for you once your equipment is in
operation, offering you a range of services that includes everything from maintenance to training.
Our 2013 financial results show that we are on the right track with this strategy. I would like to take
this opportunity to thank you, our customers, for these excellent results. It is the trust that you continue to put in us, along with the ideas that emerge from our everyday work together, that motivate
us and spur us on to be innovative.
The success stories gathered here in the 2014 packazine will give you a taste of the successful
collaboration. Yogurt, cookies, lozenges or vaccines – Packaged as promised. Bosch.
I hope you enjoy reading the new packazine.
Friedbert Klefenz
4 | packazine News Facts & Trends
Diabetes Care:
fighting a global pandemic
Diabetes mellitus is the first non-infectious disease that has taken on the magnitude
of a pandemic. It is estimated that the number will increase from 382 to 592 million
people with diabetes by 2035. Nevertheless, diabetes research has made great progress
in recent years. The once deadly disease has become one that is chronic.
New, targeted therapies and application technologies for insulin administration have
given back some flexibility in everyday life to patients.
In type 1 diabetes, the body’s own immune cells are directed against the insulin-producing beta cells of the islets of
Langerhans in the pancreas, often already in childhood. The resulting insulin
deficiency always requires insulin therapy. Type 2 diabetes today accounts for
about 90 percent of all cases. Obesity
and lack of exercise lead to a resistance
to the insulin hormone, preventing it
from working properly on the cell membranes and from transporting glucose
into the cells. The result is increased
blood glucose concentration, which often goes unrecognized for many years.
Changing diabetes therapies
All approaches to diabetes therapy have
always been aimed at controlling blood
sugar levels and preventing large fluctuations down (hypoglycemia) or up (hyperglycemia). Today, insulin is obtained
packazine | 5
from bacteria using biotech methods and
Focus on safety and output
brought to the market as human insulin.
Pens are currently the most widely used
cessing of cartridges for insulin pens
A very significant progress was domestic
system for insulin injection. For diabetes
particularly in the so-called “pharmerg-
driven the use of machines for the pro-
self-monitoring of blood glucose in the
patients, easy and safe handling of the
ing” markets. The criteria by which
1980s. Further milestones include the
pens is the most important criterion.
manufacturers choose their machines
approval of so-called insulin analogs, that
Insulin manufacturers in turn must pay
are high output, high availability, and
work particularly quickly or uniformly, as
particular attention to a comparatively
reproducible precision in insulin produc-
well as insulin pumps, which continu-
inexpensive production, sterile filling
tion. Filling and closing machines for car-
ously and flexibly provide diabetes type 1
and the integrity of the materials used
tridges with a capacity of up to 600 units
patients with short-acting insulin.
by reducing manual intervention during
per minute are now considered state-ofthe-art. Modern plants and lines are
Moreover, insulin pens were developed
the production process as much as pos-
for more ease of delivery. They are used
sible. Modern barrier technology com-
compatible with all current filling tech-
as multiple application systems with
pletely seals off products, processes,
nologies and partly also equipped with
pre-filled insulin cartridges. For diabetes
equipment and operators from each
combi filling stations for different drug
patients, the independent administra-
other. Insulin manufacturers also in-
requirement and packaging types.
tion of insulin is now a lot easier. Due to
creasingly rely on the use of isolators,
their shape, the pens can not only be
which ensure higher product quality at
Passing all processes unscathed
transported more conveniently, they can
lower cost compared to conventional
In all process steps, the cartridge is
also be applied “en route” without at-
cleanrooms.
exposed to different temperatures, pres-
tracting attention. Patients are able to
In addition to the omnipresent cost fac-
sures, and movements. The higher the
better adapt the therapy to their own
tor, the growing number of diabetes pa-
speed of a filling and closing machine,
rhythm of life.
tients in the emerging economies has
the more the glass is exposed to physi-
6 | packazine News Facts & Trends
cal stress. This can cause damage to the
Precise filling and inspection
to be easily transferred to production
glass, such as cracks, chips, or fractures.
For a full and bubble-free filling 80 per-
systems via scale-up. Inspection is
These defects result in product loss and
cent of the maximum quantity is dosed
equally important: empty and full glass
higher costs for pharmaceutical produc-
into the cartridge before the remainder
containers can be quickly and accurately
ers, which machine manufacturers are
is filled to the full point by laser-scanning
inspected for particles in the liquid or
counteracting with new solutions for
the cartridge neck. The laser sensor
for cosmetic defects.
gentle processing. The primary objective
switches off the dosing when the fluid
is hence to minimize contact between
meniscus reaches the laser beam.
Significantly improved quality of life
glass containers.
100-percent inspection plays an impor-
It is still uncertain when alternatives to
During loading of the cleaning machine,
tant role for the exact closure of the car-
injecting insulin will prevail. But the near
for instance, the cartridges are trans-
tridges. With the “Static Division” (SD)
future already promises the introduction
ported in so-called transport pucks in a
technology, light is projected through the
of further insulin formulations and new,
row to prevent glass-to-glass contact.
liquid onto an optical sensor, which
improved insulin pens. Although preven-
During the sterilization process, the glass
allows differentiation between moving
tion and avoidance of long-term conse-
is exposed to an enormous heat influence,
particles and static objects, for instance
quences must always be top priority,
leading to the expansion of the glass
inhomogeneity in the glass packaging.
advances in treatment provide people
mass. This can be compensated by a con-
Automatic camera-based systems in turn
affected by diabetes with the hope of
veyor belt with flexible lateral support,
detect both particles and cosmetic
further, significant improvement in their
which widens immediately after the tun-
defects.
quality of life.
nel entrance. To protect the cartridges
Even at an early developmental stage of
from damage from tipping over, they are
insulin preparations, safe filling of car-
For more information please contact:
transported to the inlet of the filling ma-
tridges with manual and semi-automated
Dr. Johannes Rauschnabel
chine in bulk, where a star wheel sepa-
test machines has priority. It is particu-
Phone: +49 7951 402 452
rates them again. Robotic feeding and re-
larly important that these machines can
E-mail: [email protected]
moval of cartridges can provide further
be equipped with different filling tech-
reduction in physical stress.
nologies and allow the filling parameters
A key milestone in diabetes
therapies: application
technologies like insulin
pumps and pens
packazine | 7
Full speed ahead for Normon
New Hüttlin fluid bed system HDGC 600 triples batch sizes for
Laboratorios Normon while significantly reducing costs
With more than 75 years of experience
products such as antibiotics, high poten-
cooperation with long-term partner
on the Spanish market, Normon is
cy products, anesthetics, analgesics and
Hüttlin GmbH, located in Schopfheim,
among the leading pharmaceutical manu-
anti-inflammatories, which are distribut-
Germany. Hüttlin has been part of
facturers in the country. What started as
ed worldwide.
a small family business in 1937 has ex-
Bosch Packaging Technology since 2011.
Together with the Bosch brand Manesty,
panded into a corporation that now em-
Based on solid experience
Hüttlin completes Bosch’s process tech-
ploys around 1400 people who share a
With the aim of reducing costs, Normon
nology portfolio for pharmaceuticals.
production space of 80 000 square me-
planned to significantly increase its
From development to production ma-
ters. More than 90 percent of the pro-
batch sizes for certain products. The
chinery, all Hüttlin systems are designed
duction outcome consists of generic
manufacturer needed to pay close atten-
to meet customer and market require-
drugs. The production site accommo-
tion to the high quality and safety stan-
ments. The portfolio covers equipment
dates machines for manufacturing liquid
dards and economic aspects, as well as
for mixing, granulating, drying and coat-
vials, freeze-dried vials, dental cartridges,
flexible production sizes and times. This
ing, as well as comprehensive contain-
ampoules or infusion bags, as well as for
required the use of flexible and reliable
ment solutions and laboratory installa-
granules, capsules, and tablets including
technology, and resulted in a renewed
tions.
8 | packazine Customers & Markets Pharma
Normon already installed two fluid bed
systems HDG 200 in 2004 and two
further ones in 2008. “For many years,
Hüttlin has provided us with excellent
quality machinery. So the decision to
purchase an additional Hüttlin fluid bed
system was based on solid experience,”
says Gonzalo Fernández Govantes, responsible for Technical Operations and
Industrial Processes at Laboratorios
Normon, S.A. “It quickly showed that the
HDGC 600 offered the specific life science functionality we wanted, backed by
the robust technology we needed.
Normon also required a system which
provides the highest possible performance, reliability and functionality, while
giving us the flexibility to quickly make
changes to our processes. We wanted to
duce the same amount of product. In-
can simply select a new functionality
give our production a tool that moves us
cluding documentation time, the produc-
such as the coating process. All recipes
to the front of the technology race,”
tion of three batches on the HDG 200
from laboratory equipment can be easily
Gonzalo Fernández Govantes adds.
amounted to 20 hours. By tripling the
scaled-up to both the HDG 200 and the
batch size on the new HDGC 600, the
new HDGC 600. Gonzalo Fernández
Tripling batch sizes with the Hüttlin
production of only one batch now suf-
Govantes confirms, “Our staff has been
HDGC 600
fices to significantly save time and costs.
working with Hüttlin processing ma-
The Hüttlin fluid bed systems are based
Moreover, the bottom-spray technology
chines for ten years and has been trained
on a modular design. They can easily be
of the HDGC 600 with the air distri-
on the equipment. So we can realize
configured either as dryer (HD), dryer
bution plate Hüttlin Diskjet and the
changes without any additional costs.”
granulator (HDG) or dryer granulator
12 three-component spray nozzles en-
Homogenous drying results, the omis-
coater (HDGC). Therefore, the process
sure fast and uniform mixing, high spray
sion of dead zones in the product bowl
steps of drying, granulating and coating
rates, shorter drying periods and even
and preventing the product from sticking
of fine particles, powders and pellets
spray distribution as well as a minimum
and clogging to the walls are further
can be realized with one machine and
of spray losses. “Since we tripled batch
benefits for Normon.
one single product container. Before im-
sizes, we have been able to reduce docu-
plementing the Hüttlin HDGC 600 at its
mentation, the number of quality control
Smooth implementation
production facility in Madrid, Normon
analyses as well as working hours and
It took less than twelve months from
carried out its granulation processes on
energy consumption, and ultimately have
project kick-off until the HDGC 600 went
several smaller Hüttlin fluid bed systems.
reduced process times of up to 30 per-
into production. According to Normon’s
While Normon still uses these machines
cent,” Gonzalo Fernández Govantes
Gonzalo Fernández Govantes, “The
for certain products and smaller batch
confirms.
Hüttlin service team was constantly on-
sizes, operations for larger batches are
The HDGC 600 satisfies all Normon’s key
site to ensure a smooth implementation.”
much more efficient now with a machine
requirements. The company is able to
After carrying out first on-site tests, the
at higher production capacity. Today
mix products with different densities in
Normon only needs half the time to pro-
one single process container. Operators
Bosch team remained in place to accompany the first production batches.
packazine | 9
Normon produces more than ten different products on the new fluid bed
system. Some new products have already been approved by the Spanish
Agency of Medicines and Medical Devices (AEMPS). Normon is set to launch
new generics, and its development
teams are preparing most of these products in the Hüttlin laboratory equipment.
This equipment documents and controls
product development processes and
makes it easy to get a quick authorization for production batches. “We are
planning to build a new area for oral
dosage forms in the following years, and
we are expanding all of our manufacturing areas such as cytotoxics, hospital
or dental products. For the preparation
and roll-out of our new generics, we
need a reliable long-term partner to
support our processes,” Gonzalo
Fernández Govantes underlines. “Operating the Hüttlin HDGC 600, we can go
full speed ahead in manufacturing generics and defend our position as one of
the leading pharmaceutical manufacturers in Spain.”
For more information please contact:
Dolf Oberborbeck
Phone: +49 7622 6884 212
E-mail: [email protected]
10 | packazine Customers & Markets Pharma
packazine | 11
Packaging line revamped
Bosch Packaging Services modifies thermoforming line
for packaging of “Emser pastilles”
Even the most durable packaging ma-
which contains high levels of trace ele-
chine, a CUT 120 cartoner and a KWE
chine will need spare parts sooner or
ments, is obtained by vaporizing water
3000 checkweigher. With an output of up
later. But what is to be done if the neces-
from a hot mineral spring in Bad Ems. It
to 250 blisters per minute, the TLT 1400
sary electronic components are no longer
is offered in several dosage forms, such
processes the pastilles before they are
available? Equipment manufacturers are
as saline nasal douches, nasal spray and
packed into folding boxes and weighed.
required to inform their customers about
drops, developed to ease chronic infec-
The line’s centerpiece consists of the
available technologies and modification
tions and dry mucosae. The Emser pas-
TLT 1400 thermoforming machine, which
is characterized by its flexibility, usability,
opportunities in good time to prevent
tilles are solely available in pharmacies in
machine downtime and production loss.
five different flavors and help to moistur-
safety and high Overall Equipment Effec-
This also applied to the German company
ize and clean strained pharyngeal muco-
tiveness (OEE). A color touchscreen fa-
Siemens & Co. in Bad Ems who produces
sae caused by coughing and hoarseness.
the well-known “Emser pastilles”. Bosch
cilitates the machine’s operation; format
parts for different packaging sizes can be
Packaging Services modified the compa-
“Obsolete spare parts”
ny’s TLT 1400 thermoforming machine
For generations, Siemens & Co. has been
of tools.
within a very short time by equipping it
relying on technical equipment from
The original servo motors of the TLT 1400
with new servo motors, servo controllers
Bosch Packaging Technology to pack its
belonged to an older generation that is
and a new control system.
different salt products. For instance, the
no longer being produced. This is a mat-
Siemens & Co., based in Bad Ems, Ger-
company fills its powdery saline nasal
ter of so-called “obsolete spare parts” –
many, was founded in 1958 and has been
douches on a high-performance stick
parts and components from third party
operating as a family-run company since
pack line at rates of up to 1000 packs per
providers that are outdated or no longer
1998. It produces salt products for treat-
minute. For the Emser pastilles, Siemens
available. “Many customers need new
ing the upper respiratory tracts, espe-
& Co. uses a Bosch packaging line con-
components for their machines at short
cially the nose and throat. The mineral,
sisting of a TLT 1400 thermoforming ma-
notice. Only then do they realize that
quickly changed, almost without the use
12 | packazine Customers & Markets Pharma
certain spare parts are no longer state-
Quick support was required, as not only
and can be operated as reliably as be-
of-the-art or out of stock. So it is all the
the servo motors but also all motor con-
fore,” explains Hans-Jürgen Meisel,
more important to actively inform them
trol units and the control system needed
service engineer at Bosch Packaging
about the availability beforehand and to
replacing.
Services. Together with the customer, he
offer adequate solutions. Due to the
“Bosch Packaging Services helped us to
tested the motor and control technology
rapid pace of technological development,
bridge the time gap until the modifica-
of the modified TLT 1400 in detail, based
electronic components unfortunately of-
tion with as little production loss as pos-
on the validation protocols. As soon as
ten have a short lifespan and are no lon-
sible,” Dr. Andreas Keller recalls. “The
the last fine tuning was completed, and
ger available after only a few years,” ex-
modification itself progressed consider-
smooth operation of the line was en-
plains Andreas Herrmann, service sales
ably quicker than expected.” Instead of
sured, Siemens & Co. resumed produc-
manager at Bosch Packaging Services.
taking the estimated eight weeks, the ex-
tion of the pastilles on their TLT 1400.
With customer letters and so-called up-
perienced Bosch technicians managed to
“We would carry out another machine
grade letters published on the E-Portal,
carry out the entire modification project
modification with Bosch Packaging Ser-
the online ordering platform for spare
in half the time. After only four weeks,
vices at any time. The technicians are
parts, Bosch Packaging Services regu-
the TLT 1400 was equipped with a new
very familiar with the equipment. They
larly informs customers about the avail-
motor, control and operation technology,
planned the modification of our blister
ability of components and suggests mea-
and was extensively documented and val-
line in a competent manner and quickly
sures for preventive modifications and
idated. Moreover, the machine obtained
put it into practice,” Dr. Andreas Keller
a more powerful computer with new
confirms. Physically unchanged, the
software. To the customer’s complete
TLT 1400 in Bad Ems runs as reliably as
Modification in only half the time
satisfaction, the calculated costs were
before. “We were able to resume the
“For ten years we have been reliably blis-
also reduced by 30 percent.
maintenance.
tering our pastilles on Bosch’s thermo-
packaging of our Emser pastilles in a
very short time – and are now hoping for
forming machine,” reports Dr. Andreas
Quick resumption of production
a renewed long lifespan of our TLT 1400,”
Keller, operations manager at Siemens &
Performance tests, machine qualification
Dr. Keller concludes.
Co. “We don’t have a second thermo-
and validation completed the upgrade
forming machine at our disposal and
process. “Our customer now has a ma-
For more information please contact:
must be able to fully rely on this one ma-
chine on-site which is equipped with the
Andreas Herrmann
chine. So we faced a considerable chal-
latest drive and control technology. We
Phone: +49 711 811 57068
lenge when a servo motor broke down.”
had to make sure that it runs as smoothly
E-mail: [email protected]
packazine | 13
Affordable, high-quality
vaccines for everyone
Serum Institute of India manufactures life-saving vaccines
on Bosch filling lines
The Indian vaccine manufacturer Serum
awarded many prizes; a school in Pune
Dr. Poonawalla tackled this issue and
Institute of India has a vision – to contin-
bears his name. But his most important
has done so ever since with passion,
ually increase the production of afford-
lifetime achievement, Serum Institute of
dedication and perfection. “He has a
able, high-quality vaccines. The founder
India Ltd., was established back in 1966
very strong philanthropic character and
and owner Dr. Cyrus S. Poonawalla be-
with the aim of manufacturing affordable
through his hard work he is leading the
lieves that every child in the world
life-saving immuno-biologics for the
company by his own example,” says
should be granted access to inexpensive
entire population. After attending col-
Dr. S. D. Ravetkar, executive director,
bacterial and viral vaccines. Numerous
lege, Dr. Poonawalla, who is also a dedi-
Serum Institute of India.
humanitarian organizations and inter-
cated and well-known horse breeder in
national celebrities accompany Dr.
India, began manufacturing antitoxins at
Joint humanitarian forces
Poonawalla and his colleagues on their
affordable prices, without making any
Today Serum Institute is India’s leading
biotech company and one of the largest
charitable journey. In daily production
compromises on quality. During this
business, they rely on first-class machin-
time, these vital preventive medicines
manufacturers of vaccines in the world
ery from Bosch Packaging Technology.
were scarcely available and far too ex-
with a huge capacity of billions of differ-
Dr. Cyrus S. Poonawalla is a role model
pensive for the majority of the Indian
ent vaccine doses annually. Reaching
for many and well-known way beyond
population – with the devastating result
out to more than 140 countries, it is
the Indian borders. He has been
of many children dying needlessly.
estimated that every second child
14 | packazine Customers & Markets Pharma
immunized receives at least one vaccine
The company is the first across Asia to
Bill Gates and Prince Charles. In collabo-
produced by Serum Institute. Even
be qualified by the World Health Organi-
ration with the Bill & Melinda Gates-
newer vaccines, such as the five-in-one
zation (WHO); it supplies its products
funded Meningitis Vaccine Project, a
pentavalent (Penta) vaccine and anti-ra-
to the United Nations Children’s Fund
partnership between WHO and the inter-
bies vaccines, can now be offered at af-
(UNICEF) and the Pan American Health
national non-profit organization PATH,
fordable prices to children around the
Organization (PAHO). Serum Institute is
Serum Institute produced the new Men-
world. The manufacturer aims at target-
proud of the relationships with celebri-
ingitis vaccine MenAfriVac for the African
ing more countries every year.
ties and fellow philanthropists including
market at only 50 cents per dose.
Bosch’s filling and closing machinery
for vials, ampoules and syringes help
Dr. Poonawallas vision to become
reality: supplying affordable vaccines
to all children around the world.
packazine | 15
Dr. Poonawalla’s charitable drive has
ogy location Crailsheim, Germany. An
lines. “Bosch appreciates our feedback
influenced other dominant players within
additional FXS 2020 filling and closing
and is eager to learn from our experi-
the industry to follow his good example
line for pre-sterilized nested syringes
ence,” says Dr. Ravetkar. “Often it’s the
and will not stop until all vaccines are
was brought to Pune from Bosch in
small things that make a big difference,
affordable for the entire world popula-
China.
for instance easy documentation and
tion.
Reliability, quality and durability
validation processes and small features
Small things do matter
that make life easier for our machine
The latest project, a new FLC vial line
operators. With every project, the lines
The Serum Bio Pharma Park in Pune is
from Crailsheim, is set to be installed in
are adapted even better to our require-
the first of its kind in the country and
the next few months. The lines are used
ments.” The filling and closing lines from
was designed in strict compliance with
for various groups of vaccines, such as
Bosch have supported Serum Institute
cGMP (current Good Manufacturing
vaccines for MMR and Penta vaccines.
in coming a step closer to completing
Practice) standards. It serves as the re-
Apart from the high quality, Dr. Ravetkar
Dr. Poonawalla’s mission of supplying
search, development and production
identified further benefits, ranging from
affordable vaccines to all children
base for Serum Institute. “Needless to
a high durability and reliability to profes-
around the world. “Bosch is one of the
say, such a modern facility must be
sional service around the clock. “All
only companies who can truly act as a
equipped with highly reliable and state-
members of Bosch are dedicated to walk
full-range supplier. I believe that every
of-the-art machines,” Dr. Ravetkar ex-
the extra mile,” he emphasizes. “Repre-
company should own a line developed
plains. “Bosch is renowned for its high
sentatives from India and Germany regu-
by Bosch,” Dr. Ravetkar concludes.
quality all over the world. I have been in
larly visit Serum Institute. Many up-front
this business for many years and have
meetings were dedicated to discussing
For more information please contact:
always dreamt of having a Bosch line in
our needs.”
Dieter Bandtel
our facility.” Ten years ago, the first joint
To obtain the best possible machine out-
Phone: +49 7951 402 362
project marked the beginning of a long
put, Serum Institute and Bosch continu-
E-mail: [email protected]
and trustful relationship. The contact
ously work on slight adaptations to the
between Serum Institute and Bosch has
always been very open and personal.
Dr. Ravetkar and Friedbert Klefenz,
President of Bosch Packaging Technology,
already knew each other long before the
start of the business cooperation.
Serum Institute of India must be able to
fully rely on a highly innovative manufacturer and requires high-quality machinery, which is of paramount importance
for the safe filling and closing of life-saving vaccines. To date Serum Institute has
installed five Bosch lines in Pune. More
specifically, the company handles vials
on an FLC, an FLP and an FLM filling and
closing line; ampoules and vials are filled
and sealed on an ALF combi line, freezedry vials are crimped on a stand alone
vial capper VRK, all of which were manufactured at the Bosch Packaging Technol-
Dr. Cyrus S. Poonawalla,
founder of the institute
16 | packazine Customers & Markets Pharma
Keeping an eye on automation
How an eye drop manufacturer accelerated production with
help from Bosch
Specializing in sterile manufacturing,
new market expansion. Purchasing mul-
To meet different customer needs, Excel-
Excelvision, based in Annonay, France,
tiple storage trays dedicated to each
vision required equipment that could be
provides contract manufacturing services
product format size would have been
easily adapted for specific demands. “As
for liquid eye drop plastic vials to numer-
too costly. However, Bosch’s complete
demand increases for single-dosage
ous companies. However, to increase
line solution allowed the company to use
packaging, the new line gives us the flex-
production and capitalize on additional
one storage tray type for all product
ibility to adapt production in the future,”
contract manufacturing opportunities,
formats.
Excelvision enlisted Bosch Packaging
adds Philippe Pensuet, head of engineering and EHS at Excelvision.
Systems AG, based in Beringen, Switzer-
One trusted relationship
land, to install a fully automated packag-
Having previously used stand-alone ma-
Flexibility from primary to secondary
ing line. With significantly higher output
chines Pierre Laissy, project manager at
The bulk vial cards are first manually
capabilities, Excelvision expects to
Excelvision explains, “Bosch provided
loaded into an intelligent feeding unit,
increase production by nearly five-fold.
the consultation we needed for a suc-
which unscrambles and separates them
Excelvision manufactures vial cards in
cessful upgrade to our first highly auto-
equidistantly. The vial cards then travel
bulk, each hold five blow-fill-sealed
mated, complete line solution.” The
to the Sigpack LDF feed placer, which
single-use vials. Because the company
project also involved a lengthy approval
features delta robots that pick and place
produces different product shapes and
process with Excelvision’s customers as
individual cards into an infeed wrapper
configurations for its customers, it faced
they needed to verify that the new pack-
chain. The module is equipped with a
a logistical challenge in rapidly packaging
aging solution would meet market needs
vision detection system that ensures
the diverse products.
and regulations. During this vetting pro-
quality control of the products. It also
Prior to working with Bosch, Excelvision’s
cess, Bosch regularly consulted with
communicates with the robot picker to
previous solution was unable to keep up
Excelvision about different packaging
ensure correct product orientation.
with current demand, let alone plan for
styles and materials.
Products then move along to the Bosch
Sigpack HSL horizontal flow wrapper,
which features a long dwell sealing unit
for extended sealing time. This ensures
that the aluminum-laminated film is hermetically sealed, which is critical to protecting the blow-fill-sealed products
against water evaporation and light effects. Bosch also subjected the wrapped
cards to various tests, such as vacuum
pressure and under water submersion,
to verify that packs have an air-tight seal.
For cartoning Excelvision installed
Bosch’s Sigpack TTM topload cartoner,
which picks flow-wrapped products out
of a grouping chain and places them into
cartons. A key advantage of the Sigpack
TTM is the ability to make quick and
packazine | 17
tool-less changeovers for up to four dif-
before they are closed. In addition, the
the solution, every quality-relevant step
of the way during the process.
ferent carton formats, giving Excelvision
cartons have a tamper-evident feature,
the flexibility to accommodate diverse
making it easy for retailers and consum-
customer needs.
ers to spot packages that have been
The Sigpack TTM is equipped with a
opened.
René Kummer
leaflet carousel feeder to place
Bosch performed performance and film
Phone: +41 58 674 6776
information booklets into the cartons
tests to demonstrate the feasibility of
E-mail: [email protected]
For more information please contact:
The vial cards are hermetically sealed in
aluminum-laminated film to protect them
against light effects and water evaporation.
18 | packazine Customers & Markets Pharma
Novartis producing from the birth
Bosch supplies flexible filling and packaging line for pharmaceuticals
for Novartis in Egypt
The medicine of the ancient Egypt is one
merger of Ciba-Geigy and Sandoz. The
Safety and Environment (HSE) standards,
of the oldest documented and has signif-
company’s top-selling brands include
complying with ISO 14001 and OHSAS
icantly influenced today’s medical prac-
Glivec to treat certain types of leukemia,
18001, as well as receiving Novartis’ own
tice. Since then, medicine has evolved
Diovan to treat high blood pressure and
internal HSE award 12 years in a row.
dramatically, but Swiss pharmaceutical
heart failure, and Lucentis to treat eye
giant Novartis has been producing and
maladies.
Three in one
filling a wide range of pharmaceuticals
The Novartis plant in Cairo, Egypt pro-
However, the facility met its match trying
from Egypt for more than 50 years.
duces enough medication to meet seven
to fill and package 15 milliliter plastic
percent of the country’s market needs
bottles of Otrivin Saline Baby nose
From Switzerland to Egypt and beyond
and serves as a base for the manufactur-
drops, 10 milliliter plastic bottles of
Headquartered in Basel, Switzerland,
ing and supply chain management of pre-
Otrivin nasal spray and 100 milliliter
Novartis is one of the largest pharmaceu-
scription pharmaceuticals, as well as
glass bottles of Catafly Suspension
tical manufacturers worldwide. It was es-
over-the-counter (OTC) products. The
cough syrup. Varying consistencies from
tablished in 1996 as the result of the
Cairo facility meets the highest Health,
oily nose spray and drops to sticky cough
packazine | 19
place of western medicine
syrup presented one hurdle. The differ-
were impressed by the flexibility of the
ionizes the blowing air, which neutralizes
ent packaging formats presented another
company’s equipment and confident that
the electrostatic loads on the inner sur-
– particularly since these require differ-
Bosch had the capabilities to produce a
face of the bottles and facilitates easy
ent types of closures. While a screw cap
single-line solution for these three prod-
foreign particle removal. Because this
and measuring cup are necessary for the
ucts,” says Mohamed Galal, project man-
function is not needed for glass bottles,
cough syrup, an insert and screw cap for
ager at Novartis in Egypt.
it can be switched off easily during pro-
nasal drops and spray pump with screw
duction. The bottles then move into a lin-
cap are needed for nasal spray.
Lean and clean
ear piston filling machine equipped with
Novartis needed a solution that is highly
Bosch customized the line that met
ten nitrogen pre-flushing nozzles and ten
flexible and easy to clean during change-
Novartis’ criteria, starting with a bottle
fill nozzles. Nitrogen flushing reduces the
overs between products. Novartis en-
unscrambler, followed by an air blower
oxygen content in pharmaceutical prod-
listed Bosch Packaging Technology, a
to clean inside all three bottles and
ucts to prevent oxidation after capping.
leading provider of packaging solutions
prevent particle contamination. To clean
To allow for format flexibility, the line
for the pharmaceutical industry. “We
the plastic bottles, each blowing nozzle
incorporates three different rotary
20 | packazine Customers & Markets Pharma
capping machines, which are used de-
Bosch, which is the ideal solution to ful-
them into the cartons. These are only
pending on the product. The first is de-
fill Novartis requirements in format flexi-
some out of many functions that reduce
signed to equip each nose spray bottle
bility, short changeover times and less
machine stops to a minimum and there-
with a pump. The second rotary capping
maintenance. Novartis runs a total of 15
fore, contribute to higher uptime.
machine applies the plug to the nose
different format options for product, car-
drop bottles. The third capper is used
tons and leaflets sizes, which the Bosch
Flexibility, speed and energy efficiency
for all formats: screwing of all three dif-
CUK can easily set in a short time.
yield results
ferent caps on each bottle and placing
The cartoner’s “swing open” leaflet
Not only did Bosch’s customized system
the measuring cap on the 100 milliliter
feeder allows for the operator to quickly
for Novartis help the company streamline
glass bottle.
ensure that leaflets are correctly in place
the filling and packaging of three differ-
A key function of the line is the Cleaning-
without a second person helping from
ent products with different packaging
in-Place (CIP) Plus-system, which en-
the machine rear. Feeding of leaflets and
formats, it also enhanced production
sures repeatable cleaning results. Clean-
carton blanks are located closely to one
speed from a rate of 100 bottles to
ing must be done after every product.
another, further simplifying the opera-
140 bottles per minute for sizes of 10
From filling to capping, the line is fully
tor’s work. All cartons are positively
and 15 milliliter. For 100 milliliter bottles,
covered by a laminar flow hood that
opened by a “counter” suction head that
speed increased to 120 bottles per min-
leverages overpressure to prevent any
forms the flat cartons into three-dimen-
ute. The equipment also improved energy
intrusion of foreign particles.
sional shapes and eliminates “dead”
savings by US$ 60 000 annually with its
After the capping process the bottles are
cartons that failed to unfold. This results
advances to the bottle cleaning process.
conveyed to the labeling system, with
in the safe handling of critical carton
the exception of the pre-printed nasal
qualities, no material or product loss,
For more information please contact:
spray bottles. For secondary packaging,
and decreased production downtime. In
Kamel Meherzi
the bottles are fed into the continuous
addition, all leaflets are carried in
Phone: +49 2162 248 304
motion cartoning machine CUK from
mechanical grippers that reliably place
E-mail: [email protected]
packazine | 21
Peristaltic pump put to the test
When it comes to the filling of liquid pharmaceuticals, peristaltic pumps have
become more and more popular over recent years. While primarily used for
developmental purposes, this technology today offers a safe, clean and flexible
alternative to conventional filling systems. Allergy Laboratories, Inc. has been
successfully working with this technology for just over two years, and reflects on
some very positive user experiences.
Allergy Laboratories, Inc. was estab-
years, including a parenteral production
for vials and infusion bottles. To satisfy
lished in 1929 in Oklahoma City for the
facility for contract manufacturing. The
the company’s needs, two main require-
manufacture of allergenic extracts
company is dedicated to high quality,
ments had to be fulfilled: first, the line
needed to support the growing immuno-
strictly controlled manufacturing prac-
needed to operate with peristaltic pump
therapy practice of founder Dr. Raymond
tices, affordable products and excellent
technology; second, it had to fit exactly
Balyeat. Allergy Labs, as the company is
customer service. Allergy Labs applies
into the space that had become avail-
more widely known, has since evolved
this dedication to the manufacturing of
able by discarding an old machine. “We
into an FDA-licensed pharmaceutical
sterile depyrogenated vials, sterile dilu-
work with piston pump technology on
manufacturer of over 500 different bio-
ent and injectable drugs.
another line, which can lead to cleaning
logical extracts for the diagnostic testing
and maintenance difficulties,” says Lee
and therapeutic treatment of allergies.
Compact and clean
Beaver, director of manufacturing at
Additional manufacturing and supply
In 2010, Allergy Labs turned to Bosch to
Allergy Laboratories, Inc. “So we started
capabilities have been added over the
acquire a new filling and closing machine
looking for a filling and closing machine
22 | packazine Customers & Markets Pharma
that operates with peristaltic pump
The equipment was manufactured on
customers. While peristaltic pumps were
technology. We checked the market, and
the site of Bosch Packaging Technology
previously used for the development of
Bosch has a good reputation for this
in Minneapolis and was installed by an
small pharmaceutical batches, they now
kind of technology. The open communi-
expert engineering team from Bosch.
offer a real alternative to conventional
cation and expertise of our contacts at
filling systems. The Bosch peristaltic
Bosch facilitated our decision. They
Traditional concept revisited
pump combines the advantages of the
were always quick in responding to our
Six years ago, Bosch started to develop
traditional peristaltic concept with opti-
queries and requests, which enabled a
its own peristaltic pumps to supply the
mized dosing accuracy and a very flexi-
quick turnaround time for the project.”
growing needs of its pharmaceutical
ble operating concept. The new tubing
packazine | 23
concept of Bosch’s peristaltic pump
be opened and closed in two simple
users to conveniently run different size
makes the technology suitable for all
steps without removing any parts. The
vials without changing parts. The linear
kinds of filling operations, from develop-
operator can open the pump with one
conveyor system runs horizontally in
ment purposes to production-scale fill-
hand, change the tubing and close the
continuous motion. The containers are
ing operations. The offset alignment of
pump again. This saves time and
carried freely in the laminar-flow stream
the rollers reduces mechanical strain on
increases safety, especially for isolator
in an upright position. “The FLC line not
the tubing and permits longer periods of
applications. With the exception of the
only provides the cleanliness we require
use. Product and batch changeovers are
tubing, the system completely eliminates
for our filling operations, it also handles
easier, faster and safer. The pump can
product contact. This ensures high prod-
the vials very gently,” says Beaver.
uct quality by reducing the risk of cross-
On Allergy Labs’ FLC, the peristaltic
contamination and minimizes the poten-
pumps and a disposable tubing system
tial downtime associated with product
are fully integrated with the machine’s
changeovers.
control system, drive and controllers. An
effective alternative to conventional
A further advantage of the system is that
integrated touchscreen ensures easy
filling systems.
the low pulsation volumetric flow
and automated operations. “At first, we
ensures very precise filling tolerances.
were skeptical about the degree of auto-
As Lee Beaver observes, “filling accuracy
mation of the FLC, but its set-up was
is one of the technology’s main bene-
easy: our operators quickly adapted to it
fits.” Allergy Labs mainly uses the Bosch
and it’s pretty much maintenance-free,”
filling and closing line for water-based,
Lee Beaver explains. Bosch recently vis-
easily soluble products such as inject-
ited Allergy Labs to perform preventive
able, sterile generic drugs. The Bosch
maintenance work on the machine.
peristaltic pump is suited for filling vol-
“There was just not much to service,”
umes of 0.1 to 30 milliliters. The pump
Beaver confirms. “The line has been in
can also be modified to handle even
operation for over two years now, but it
smaller sizes, flexibly adjusting to each
didn’t take us that long to recognize the
manufacturer’s requirements. “Allergy
key benefits for us: safe and reliable vial
Labs operates with 2 milliliter fills, so
handling, filling accuracy of the peristal-
filling accuracy was a big concern for us.
tic pump technology and the cleanliness
But Bosch met all of our specifications,”
of the entire process.”
Peristaltic pumps today offer an
Beaver explains. “Filling operations are
drip-free, and the single-use compo-
For more information please contact:
nents significantly contribute to clean
Jamie Schroetter
handling.”
Phone: +1 763 493 6773
E-mail: [email protected]
Pretty much maintenance-free
Along with the peristaltic pump, Allergy
Labs opted for a new filling and closing
line from the FLC series. The FLC 3080
filling and closing machine is designed
to fill, sample check-weigh and stopper
vials in a continuous motion process.
The FLC 3080 uses a vacuum star wheel
to accurately position each vial for capping. Additional features include a
“V-cleat” conveyor system that enables
24 | packazine Customers & Markets Pharma
Flexible solutions
for complex formulations
Cipla relies on Bosch capsule filling machine GKF 2500 ASB 100%
Cipla, one of the largest Indian pharmaceutical manufacturing companies, has
experienced a boost in demand. To enhance its filling capacities, Cipla chose a new
capsule filling machine from Bosch Packaging Technology.
Cipla was established in 1935 and
local demand is continuously growing,
today is one of the world’s largest
the same accounts for drug exports.
generic pharmaceutical companies
India already is a global leader in the
with a presence in over 170 countries.
generic drug market, and national
The company started business with
companies are currently expanding their
the vision of making India self-reliant
sales to other emerging markets, as well
and self-sufficient in healthcare, and
as the United States and Europe.
now manufactures over 2000 products
in 65 therapeutic categories and more
The best match
than 40 dosage forms, including tablets
Following the demand of the developed
and capsules, pre-filled syringes and
markets, many companies have invested
other pharmaceutical APIs. Cipla is well-
in sophisticated machinery to meet
known around the world for producing
the more complex requirements. “The
affordable, high-quality medicines that
regulations are very strict and we must
meet the needs of patients across
focus on high quality to be able to
therapies.
compete with local providers,” Sudhir
Sudhir Gule, head of Cipla’s Kurkhumbh
Gule explains. Cipla is well-positioned
plant, points out that “India has
to answer the demands both locally and
seen a paradigm shift over the past
globally. Over the past years, the com-
15 years. We now have one of the best
pany has also continuously equipped
pharmaceutical industries in the world.
its plants with new high-performance
This has led to numerous changes and
machines.
an increase in the sophistications of our
For more than ten years, Cipla has been
formulations and exports.” While the
one of Bosch’s key customers in India
packazine | 25
and uses different generations and
the cGMP-compliant production cabin
Adapting to market requirements
types of GKF filling machines, as well as
is easily accessible for user-friendly
“Our team is very satisfied with the new
several KKE checkweighers at different
operation and cleaning. The automatic
capsule filling machine. It is not only
production sites across India. The latest
trouble-shooting features ensure the
especially user-friendly. It also gives
successfully completed project is the
highest pharmaceutical safety: deformed
us the flexibility to adapt to market
installation of a new capsule filling ma-
or damaged capsules are removed even
requirements and to quickly switch
chine at Cipla’s Kurkhumbh plant. “Just
before they arrive at the filling station.
from one product to another without
as we do for all our machines, we went
During capsule closing, the capsule
long changeover times. Moreover its
through a rigorous selection procedure
body scanner recognizes incomplete
compact design helped us to optimize
and compared the relevant data of dif-
capsule portions.
our working space. Last but not least,
ferent machines available in the market,”
The GKF 2500 ASB 100% is equipped
the online checkweigher ensures exact
Sudhir Gule emphasizes. “The GKF 2500
with a high-precision gravimetric online
filling weights, which is an important
ASB 100% was the best match for our
weight control system, which controls
requirement for us and our customers,”
requirements and our experience proves
the weight of every single capsule.
Sudhir Gule underlines.
us right.”
Based on communication between
the checkweigher and the dosing sta-
For more information please contact:
Highest safety and precision
tion, the analysis software calculates
Andreas Nüssle
Ergonomic, clean and secure handling
an average filling weight from and
Phone: +49 711 811 57886
is at the heart of the GKF 2500 ASB
compares it with the theoretical filling
E-mail: [email protected]
100% capsule filling machine. It is suited
weight. Only those capsules whose
for a vast amount of products with an
weight is within the pre-set tolerances
output of up to 150 000 capsules per
are accepted, all others are rejected
hour. Its modular design facilitates quick
automatically.
changeovers and high productivity;