A major Russian drugmaker deployed a SIEMPHARMA counting-filling line for tablets and capsules with a capacity of up to 50 jars per minute.
A major Russian pharmaceutical manufacturer launched a new product line and, to scale production, set up a section for counting and packaging tablets and capsules into plastic jars followed by carton packing. Industrial equipment supplier IST-PAK acted as the technical partner, selecting, supplying and commissioning an Italian counting-filling line by SIEMPHARMA SRL.
The key challenge was fitting modern high-performance equipment into an operating shop floor with severe space constraints. The customer had no room for expansion or reconfiguration, while the product range required support for many packaging formats. Another condition was strict compliance with an approved budget.
After evaluating several options from different manufacturers, the choice fell on the Italian filling-and-capping monoblock: its ergonomics and multifunctionality allowed all line components to be installed in the existing space without reconfiguration while delivering the required throughput and flexibility.
The line performs the full cycle of operations:
- automatic plastic jar feeding and compressed-air purge;
- inspection, automatic counting and filling of the required number of tablets and capsules;
- capping, labeling and carton packing with automatic leaflet insertion.
The equipment works with 8 jar formats and 7 carton formats, enabling up to 24 filling combinations. Line capacity is up to 50 jars per minute at a filling speed of 30 to 168 tablets/capsules per minute.
IST-PAK engineers also integrated a machine-vision system into the monoblock that inspects every tablet and capsule before filling, detecting and rejecting substandard units without stopping the process. This minimized operator involvement in quality control and kept defective products out of the jars.
During the project, engineers performed commissioning and SAT testing under real operating conditions, as well as IQ and OQ qualification, which is critical for GMP-compliant production. Customer staff were trained in line operation, changeover procedures and maintenance.
“We did not just select a configuration for specific tasks but acted as a link between the customer and the manufacturer. In the end, the customer got not only a working line but also full support and a trained team,” says IST-PAK CEO Alexander Grinchenko.
The project’s outcome was not only installed equipment but a competent customer team. The line reached target capacity without downtime, allowing the company to launch a new product range, increase output and cut costs through automation.
Source: RBC Companies
