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SRD
BOLANG
20240315SRD
SRD-1/1200 non-PVC film soft bag large infusion automatic production line
SRD-1/1200 non-PVC film soft bag large infusion automatic production line
Specification
SRD-1/1200 soft bag large infusion automatic production line renderings
Plan view of SRD-1/1200 soft bag large infusion automatic production line
Schematic diagram of interface position of SRD-1/1200 soft bag large infusion automatic production line
SRD-1/1200 type soft bag large infusion automatic production line foot installation diagram
二、The main technical parameters:
Actual production capacity: 1000-1200 bags/hour; (500ml steady speed 1000 bags/hour; 250ml, 100ml steady speed 1200 bags/hour)
Measurement error: 500ml≤±0.7%; 250ml≤±1%; 100ml≤±1.5%; (measured by mass flow meter);
CIP/SIP In-place cleaning and disinfection: 125℃~30 minutes;
Liquid temperature and pressure: max.50℃, 2~4kg/cm2
Bag-making film: NON-PVC double-layer composite film;
Film thickness: 190±20um (thickness deviation max.10%);
Inner diameter of membrane cylinder: min.150mm;
Maximum outer diameter of membrane cylinder: max.600mm;
Production specifications: 100ml, 250ml, 500ml (other specifications need to be specially made);
Bag-making form: single tube, heat-sealed;
Printing method: hot foil printing;
Capacitance: 13.4kw, 380v, 50Hz;
Compressed air: pressure 6Bar (dry without oil), consumption: 1000L/min;
Clean air: pressure 4Bar (dry without oil), consumption: 500L/min;
Cooling water: 100L/hour, 15-20℃;
Noise: max.75dB;
Relative humidity: max.50%;
Average humidity: %85;
Ambient temperature: max.24℃;
Operation menu text: Chinese/English
Material: Ultra-low carbon austenitic stainless steel at the contact with the liquid, and the rest are basically low-carbon austenitic stainless steel
Dimensions: 4.21mX2.1mX2.1m (length X width X height)
三、Main accessories:
Pneumatic components
NO. | Name | Qty | Specification | Picture | Supplier |
1 | main valve island | 1 | With fieldbus interface, with PLC Simple and reliable connection and stable performance | ||
2 | Formed valve island Filling valve island | 1 | Stable performance and long service life | ||
3 | Linear drive unit | 1 | Stable performance and long service life | ||
4 | cylinder | Several | Stable performance and long service life | ||
5 | air gripper | 2 | Stable performance and long service life | ||
6 | hydraulic buffer | 2 | Stable performance and long service life | ||
7 | Air source treatment device | 1 | Stable performance and long service life | ||
8 | joint | Several | Stable performance and long service life | ||
9 | server system | 2 | Stable performance and long service life (Lenz, Germany / Schneider, Germany) | ||
10 | Air tube | Several | Stable performance and long service life | ||
11 | Magnetic switch | Several | Stable performance and long service life |
2、Other major components
NO. | Name | Qty | Specification | Picture | Supplier |
1. | PLC(With temperature control module) | 1 | Siemens, Germany | ||
2. | Color touch screen | 1 | Siemens, Germany | ||
3. | Reducer and brake motor | 2 | Germany SEW | SEW EURODRIVE | |
4. | vacuum generator | 1 | Germany FESTO | ||
5. | timing belt | 1 | Germany BRECO | BRECO | |
6. | Diaphragm valve | 7 | germany gemi |
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7. | Mass flowmeter | 1 | Swiss E+H | ||
8. | Reinforced silicone tube | 1 | Saint-Gobain, France American Temple | ||
9. | Linear guide pair | 5 | Taiwan | ||
10. | Incremental encoder | 1 | German P+F Koyo | ||
11. | Temperature control instrument | 8 | B.C | ||
12. | Photoelectric switch | several | Germany SICK |
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13. | proximity switch | several | Germany TURCK |
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14. | Linear Bearings | several | igus Germany | ||
15. | Hydraulic booster cylinder | 2 | Tox, Germany | ||
16. | slot switch | 1 | Germany SICK | ||
17. | Flow Switch | 1 | Japan SMC | ||
18. | heating module | several | France SELCUC | ||
19. | breaker | several | ABB Sweden Schneider, Germany | ||
20. | contactor | several | ABB Sweden Schneider, Germany | ||
21. | relay | several | Japan OMRON Schneider, Germany | ||
22. | Terminals | several | PHOENIX, Germany |
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23. | Heating pipe | several | Japan | ||
24. | drag chain | 2 | Germany | ||
25. | stainless steel | several | Japan | ||
26. | anti-loose pad | several | Germany |
四、Performance characteristics:
1. Compact structure and small footprint.
2. The machine is controlled by PLC programmable controller, with powerful functions, perfect performance and complete intelligent control.
3. Multi-language (Chinese, English or other) touch screen operation, with a good man-machine dialogue interface. All process parameters closely connected with production such as welding temperature, time, pressure; various parameters required for printing; various parameters of filling, online cleaning and online sterilization can be set directly through the touch screen, and can be set according to customers The external printer is required to output various parameters.
4. Fast signal response system, the control and detection signals of the solenoid valve are concentrated in one piece through the valve island, and connected to the controller through the field bus. This structure realizes the most economical wiring method, the fastest signal transmission and Easiest on-site maintenance.
5. The main transmission mechanism of the drive system of the entire production line adopts the combination of imported servo motor reducer and synchronous belt, with high precision and accurate positioning. It adopts non-contact heat-melting sealing, which is pollution-free and tightly sealed, and can be discharged into the bag before sealing. Air, using advanced filling method (mass flow meter), the measurement is accurate, and the filling amount of each filling head can be set or changed through the man-machine interface, and the measurement adjustment is convenient.
6. The pneumatic system adopts unified air intake and centralized exhaust. It not only reduces pollution and noise, but also has reliable layout and beautiful appearance.
7. The intelligent control is powerful. When the parameters of the set point (such as printing, bag making, filling, welding) exceed the set value, the machine will alarm.
8. Perfect fault search and feedback function. When the equipment fails during operation, the program can immediately search for the fault point and display it on the touch screen. The fault display is intuitive and easy to find, which can help the operator to deal with the fault in time.
9. Good storage and memory function. The welding system and filling system have the function of recipe storage and recall. For different film materials and different filling media, the user can store the actual welding experience values and filling parameters in advance. When encountering similar production situations in the future, the stored experience parameters can be directly called, and there is no need to re-adjust the parameters. .
10. Unique online cleaning and online sterilization system, which can save cleaning time and ensure sterilization effect. The time, pressure and temperature of online cleaning and online sterilization can be adjusted directly on the touch screen according to the needs of the product.
11. The parameter setting function has a self-protection function. Not only can various parameters in the operation of the equipment be easily and intuitively queried, modified and monitored on the touch screen, but also the set parameters such as temperature can be preset with the maximum and minimum values. to avoid human error.
12. It can produce infusion products of different specifications (including 100ml, 250ml, 500ml, 1000ml, etc.), and the replacement of specifications is convenient, simple and fast. The equipment only needs to replace the mold and printing plate when changing specifications during the production process, which can achieve professional The need for mass production.
13. Use high configuration to reduce the failure rate. In order to reduce the failure rate of the equipment during operation and ensure the continuous operation of the equipment, the servo system, electrical accessories, PLC, pneumatic components, and power components all use well-known foreign brands.
14. Good adaptability of consumables, the equipment has good applicability to various brands of consumables used in production, such as non-PVC film materials, printing ribbons, mouth tubes (or hoses) and combined sealing covers.
15. The whole machine is basically made of stainless steel, the contact with the liquid is ultra-low carbon austenitic stainless steel, and the rest are basically low carbon austenitic stainless steel, which meets the requirements of GMP.
五、Introduction of equipment system - main station and structure principle:
The equipment can produce 1 bag at a time (according to different production and loading requirements, the production line can also produce 2 bags, 3 bags, 4 bags, 6 bags or more bags at the same time), The production line is mainly composed of automatic film feeding mechanism, printing mechanism, forming mechanism, primary welded pipe mechanism, secondary welded pipe mechanism, bag cooling and separation mechanism, mouth pipe fixing clip turning mechanism, mouth pipe conveying mechanism, mouth pipe preheating mechanism , Main conveying mechanism, filling pipeline system, cleaning-in-place (CIP) and sterilizing-in-place (SIP) system, bag pressing mechanism, cap feeding group, heating group, emptying group, bag discharging group, bag discharging track, automatic Control part and other parts. It mainly completes the functions of automatic film feeding, printing, automatic mouth feeding, mouth tube preheating, thermal synthesis, mouth tube welding, bag separation, bag indexing, filling, automatic cap feeding, heating sealing, bag discharging and other functions. The production line also has no film shutdown, no bag mouth shutdown, no ribbon shutdown, can not start when the temperature does not reach the set value, air pressure soft start, automatic shutdown when the air pressure is lower than the set value The adjustment and filling pipeline can be cleaned in place (CIP) and sterilized in place (SIP), no bag without cover, no bag without cover and other functions. Later, according to the actual needs of each manufacturer, auxiliary equipment such as soft bag transportation, upper and lower sterilization trolleys, sterilization, drying, leak detection, light inspection, boxing, and packaging can be equipped.
3、Main station and structure principle:
3.1 Film station
The upper film station is the first station of the equipment. Its function is to provide standard non-PVC film rolls of various specifications and sizes to the following stations under the control of the prescribed procedures. Membrane. It consists of three parts: unwinding drum, buffer drum and guide drum. The film roll is fixed by a pneumatic tensioning shaft, the German SEW motor drives the rolling and stopping of the film roll, and a buffer rod controls the smooth running of the film during the pulling process. . When the film roll is exhausted or the film material is broken, the equipment has automatic detection and feedback functions, which can realize no film alarm.
3.2 printing station
The printing station belongs to the hot stamping technology, which mainly uses the method of heating and pressurizing to peel off the pigment peeling layer on the ribbon from the ribbon substrate, and then transfer it to the outer surface of the non-PVC film by sublimation, dyeing, adhesion and bonding, so as to make the soft bag The name of the medicine, the date of manufacture, the batch number, the expiry date and the content related to the medicine are printed on the outside. After heating the printed copper plate (with product name, specifications, instructions for use, precautions, approval number, etc.) and movable type (production date, expiration date, approval number), the color is transferred to non-PVC by heat transfer. On the membrane, the adjustment and batch number of the membrane plate, the replacement of the production date and the effective date are very convenient, which can greatly improve the production efficiency. The consumption of the ribbon is precisely controlled by the encoder, which can save the ribbon to the greatest extent.
3.3 Film drawing station
The film pulling action in the film pulling station is completed by the electric linear drive unit driven by the servo motor. During the conveying process, the non-PVC film is clamped by the air gripper, and the drive of the servo motor can ensure the accurate conveying of the film material. While the film material is being conveyed, the film material is divided into two layers by a fixed film dividing knife to ensure that the boat-shaped interface is accurately placed into the film material during the movement.
Compared with the suction cup pulling method used in the old technology, the film pulling method using the mechanical gripper not only has a higher success rate, but also can be maintenance-free.
3.4 bag making station
The work done by the bag making station is to weld and cut the periphery of the bag completely, and these two actions are completed by the Tox gas-liquid booster cylinder made in Germany. The printed non-PVC film and the preheated interface are simultaneously transferred to this station under the control of the program. The gas-liquid booster cylinder drives the upper mold to move rapidly, and the periphery of the soft bag and the interface are heat-sealed, and then the booster cylinder transfers the force. Stroke, cut the bag into shape. The tools used in this station are imported from abroad, with stable product quality and long service life.
The station adopts a new type of mold structure. All molds are embedded with heating rods and thermocouples for uniform heating and accurate feedback, which reduces heat loss. When replacing molds to produce products of different specifications, only the upper mold needs to be replaced, and the lower mold is an adjustable mold, which can greatly save replacement and debugging time.
3.5 Interface conveying station
The interface conveying station is specially used to provide a ship-type interface by a hopper, and the hopper automatically sends the interface to the interface.
To the interface slideway, pinch device, timing belt until it is sent to the two-layer non-PVC film opened by a special film opening tool. The station uses a new positioning method to control the conveying of the interface, so as to ensure the precise position of the interface when it enters the middle of the film
3.6 Interface preheating station
Because the material of the ship-type interface is different from the membrane material and the wall thickness is not uniform, in order to ensure the compatibility between the interface and the membrane.
Rely on heat sealing to reduce the chance of micro-leakage. The interface must be preheated at this station first, and by adjusting the preheating temperature, the film material and the interface must be welded at the best temperature.
3.7 Interface welding station
The mold movement of the interface welding station requires smooth and fast movement. Here, the welding die is driven by the special guide cylinder of FESTO company in Germany, which ensures the smoothness and speed of the operation. The heating rod and thermocouple of the mold in this station are directly installed on the mold, which not only heats evenly and provides accurate feedback, but also reduces heat loss and saves energy. At the same time of welding the mouth tube, another group of guide cylinders drives the cooling plate to cool the surface of the soft bag, making full preparations for the following shaping station.
3.8 Interface shaping station
When the welded bag runs to this station, the welded interface is reshaped with a mold that is completely consistent with the interface. At the same time, the air gripper clamps the leftover waste from the bag making to tear it off, so that the bag is completely formed and the triangle is formed. The scrap is collected by a special catching device. with automatic
The scrap edge tearing station can not only reduce the negative impact of artificial scrap edge tearing, ensure that the bag shape is beautiful and generous, but also can effectively protect the mold surface and the damage caused by the cutter during use, and prolong their service life.
3.9 Fixture flip station
The station passes the conversion device to make the fixture turn over
Rotate 90 degrees, while also making the soft
The bag is turned 90 degrees to facilitate filling and sealing at the back.
3.10 filling station
This station is completed by the internationally advanced Swiss-made E+H mass filling flowmeter. The filling accuracy is very high and can fully meet the requirements of the National Pharmacopoeia. .This station adopts a high-pressure filling system. The filling pressure is controlled by a variable frequency speed-regulating pump, and the filling pipeline is connected by a medical high-pressure silicone rubber tube (see the figure on the next page). Steel wire to strengthen the strength, high pressure resistance up to 4 kg / square centimeter. In the process of use, it can be anti-aging and not deformed, thus ensuring the production speed.
In addition, the station also has on-line cleaning and on-line sterilization functions.
The online cleaning and online sterilization system configured by this machine can greatly save the cleaning time and ensure the sterilization effect. During the cleaning process, the interior of all parts that come into contact with chemicals can be cleaned. During sterilization, the temperature can be adjusted up to 121°C according to the user's needs without causing any damage to the filling pipeline system. The station is easy to clean and disassemble. Users can also choose a printer to print and archive the data of the online cleaning and online sterilization process.
3.11 capping station
The production line uses a combined sealing cover, which transports the cover to the cover feeding chute through the vibrating hopper, and then reaches the predetermined position. After the heating effect of the heat setting is reached, press the cover onto the interface. Before welding the cap, in order to discharge the residual gas in the bag after filling, an automatic exhaust system is specially designed, which can adjust the exhaust according to the actual situation.
3.12 output station
This station is to remove the filled soft bag products from the filling line with an air gripper, and place the qualified soft bags smoothly and neatly on the parallel conveyor belt through the rodless cylinder drive unit with guide. Unqualified products for equipment self-inspection will be automatically discarded into the waste bag collection box.
3.13 Electrical control cabinet (as shown below)
Adopt advanced PLC control and integrated valve island control mode, simple circuit, action response
Fast, safe and reliable operation. After the bag making, filling and sealing is made into an all-in-one machine, only one set of electricity is needed.
control system and a set of man-machine interface operation unit, thus reducing more than one equipment operator,
It avoids the bad factors of safety accidents caused by the uncoordinated operation of two people, and enhances the equipment.
security and reliability.
3.14 How cleaning-in-place (CIP) and sterilization-in-place (SIP) systems work
Cleaning-in-place and sterilization-in-place are composed of pipeline system, control valve, control system and gas-liquid separator. When the switch valve is opened, the water for injection enters the pipeline system from the liquid medicine port, and discharges the pipeline from the switch valve to realize the cleaning of the pipeline. When the on-off valve is closed and the steam enters the pipeline system, the water generated by the steam is discharged from the pipeline through the trap to ensure that the temperature and pressure of the pipeline system can meet the sterilization requirements. The cleaning time, temperature and other parameters can be displayed and controlled by the system.