So that the filling in the cleanroom does not become a bottleneck

Machine complete © gustav-obermeyer.com

Foreground Input Station © gustav-obermeyer.com

Here the filling and screwing take place © gustav-obermeyer.com

Product samples © gustav-obermeyer.com

Figure 1 - Compact fully automatic machine in the cleanroom - Good bottles (IO) are conveyed for secondary packaging. Defective bottles (NIO) remain in the filling room for inspection.

Demographic change, highly fluctuating order volumes, short or accelerated delivery times – those who can, develop their manual or semi-automatic filling systems towards fully automatic ones. But what about, for example, space requirements?

Production areas in the hygienic sector and especially in cleanrooms are expensive and thus scarce. They should always be used optimally. The challenge is to utilize existing space as efficiently as possible, and machine manufacturers can make a significant contribution with clever concepts. At the same time, the requirements from ongoing production are diverse. At manual workstations, the quality of the product largely depends on the working method, thoroughness, skill, and relevant experience of the operator. Not only repetitive strain from the same hand movements during larger batch sizes can cause manufacturing errors with all known consequences and follow-up costs. Automation is therefore often worthwhile.

The following introduces two different approaches to the overall machine concept that can lead to the desired goal even with very complex and individual requirements of the fill goods, packaging, and customer site conditions:

Linking independent modules

In this variant, the machine manufacturer offers proven modules for the individual sorting, filling, and packaging steps as a chain. The more complex the task, the longer the module chain. The interfaces are clearly defined and flexible. They ensure a safe production process. One module could be a linear filler, another a capping unit with screwing device, e.g., in carousel design. Additional pre- or post-processing modules for container cleaning, primary packaging inspection, or serialization can be integrated. Advantages of this concept typically include optimized throughput and easier service due to standardization of the components. However, this is countered by the relatively large investment volume in the sum of the individually deployable modules and the resulting higher space consumption in the cleanroom. If sales figures fall short of expectations after the investment, this can significantly negatively impact the return on investment metrics.

Combining functional modules

The second approach aims to combine individual functional modules into a machine frame. The result is compact filling and capping systems that share common elements. Each machine becomes a unique unit because the functional modules are optimally adapted to customer requirements. The machine’s external form can also be tailored to the spatial conditions at the customer site. For example, the operator’s position or the direction of the incoming or outgoing product flow can be individually chosen. Based on the jointly developed specifications, customer and designer select the best concept for container transport from various options, to stay with the example. For compact machines, round turntables or revolver arrangements are widespread, but linear solutions using conveyor belts or star feeders are also feasible. Although this approach usually involves greater consulting effort and more complex customization, a particular advantage of the combined functional modules is that a machine with low space consumption is created. Additionally, special functions can be easily planned or prepared for later retrofitting, as there is no tight space constraint in this solution approach. Anything conceivable can be implemented to meet the requirements.

For a customer in the pharmaceutical industry, Gustav Obermeyer GmbH & Co. KG in Plauen, Saxony, used the second approach to design a particularly compact system. Only about 12 m² of total space was available in the cleanroom. The goal was to accommodate a bottle filling and capping machine for powder on this limited area. Limiting the fully automatic system to the width of the room was a major challenge. All elements that need to be monitored and filled by the operator were aligned on one side. The side of the machine facing away from the operator had to be directly against a wall. Consequently, only components that require very infrequent access could be installed on the wall side. Behind the wall is the space for secondary packaging. Good bottles or IO bottles can only pass through the machine into this neighboring room; defective bottles or NIO bottles are transported along the cleanroom wall via a conveyor belt around the machine into the operator’s reach.

The customer was able to increase the output from a maximum of 8 bottles per minute at manual workstations to 35 bottles per minute with the fully automatic system, tailored to their spatial conditions and packaging process specifics. The operator thus experiences a necessary relief, and the machine now reliably monitors the quality of each individual bottle without fatigue. The employee only needs to intervene in case of malfunctions or for cleaning.

With four times the production capacity now available, significantly higher sales figures are possible, and larger batches can be produced and brought to market much faster. The well-trained staff from the former manual filling now handle higher-value tasks. They are pre-trained to undertake more demanding activities such as machine setup and reconfiguration. New employees, still unfamiliar with company-specific details, can easily learn to operate the machine through the large touch HMI with symbols and images. Different types of control stations continuously and reliably monitor the filling and packaging processes. User management with various permission levels and an integrated audit trail support secure quality production.