Liquid filling, pl ing, capping and packaging production line of 5-15ml sterile eye drops bottle

Flow chart：

 

1，Overview

The eye drop aseptic filling production line can complete such procedures as bottle unscrambling, conveying, aseptic purified air bottle washing, filling, inner stopple feeding, outer cap turning, lamp inspection, labeling, cartoning, weighing and detecting, film wrapping case packing and palletizing. The whole filling production process is completed under the 100 grade laminar flow protection and aseptic isolation, and isolation protection of each area ensures aseptic production of eye drop products, conforming to the new version GMP requirements. The production line is also applicable to production of other small volume products in plastic bottles. The production line inherits internationally advanced technology in its structural principle, and incorporates various patented technologies with independent intellectual property rights. It has reached the advanced level and can replace similar imported products.

 

2, System components

- Bottle storage and automatic bottle unscrambling system

- Bottle conveying and fallen bottle eliminating system

- Static eliminating and bottle air washing system

- Static eliminating and stopple or cap air washing system

- Peristaltic pump or ceramic pump filling system

- Vacuum stopple sucking and stoppling system

- Mechanical hand cap grabbing and capping system

- Pneumatic gripper constant torque positioning cap turning system

- 100-grade laminar flow aseptic protection system

- Dust particles and airborne microbe detection system

- Lamp inspection machine, labeling machine, cartoning machine

- Case packing machine, palletizer and other back end-of-line packaging equipment

 

3，Mature cutting-edge technology

- The advanced PLC system realizes full-line automatic control and operation.

- The design that the bottle surface is ultra-high from the table ensures that the laminar flow will not flow back on the bottle mouth. The shape of all parts on the table is designed to be easily cleaned without any dead corners.The functional stations of the equipment are completely operated under laminar flow protection, fully conforming to GMP requirements.

- The automatic bottle unscrambling mechanism adopts curved design. Whether for round bottles or for flat bottles online unmanned operation can be realized with high efficlency.

- Aseptic purified air is used for air washing of the bottle, inner stopple and outer cap. The ion wind eliminates static electricity attached on the bottle, inner stopple and outer cap. The air washing and bottle distributing device carries out air blowing on one way and back sucking on the other way, so as to ensure cleanliness of the bottle, inner stopple and outer cap.

- The advanced ceramic pump or peristaltic pump filling mechanism is featured by convenient and reliable disassembly, cleaning and sterilization. Servo motor is adopted for driving and touch screen for metering adjustment. The advanced bottle distributing and bottle mouth clamping and aligning device ensures that the filling needle is inserted into the bottle for filling and that there is no abnormal situation such as bottle falling.

- The integrated mechanism of the advanced mechanical hand vacuum inner stopple grabbing, tracking, positioning and inner stopple feeding device and the mechanical hand outer cap grabbing, tracking, positioning, outer cap feeding and outer cap turning device runs stably and reliably. The air gripper type cap turning head is used for cap taking and cap turning with adjustable torque, meeting the requirements of different outer caps. The continuous rotary structure is adopted for inner stopple feeding and outer cap turning to ensure production efficiency. t is provided with mature labeling, labeling, cartoning wrapping, case packing, palletizing and other automatic back-end-of-line packaging equipment.

- The transmission components of the equipment are mainly gears and lever linkages of slow-stroke transmission, ensuring running stability and reliability of the equipment. The machine is almost noise-free

- Continuous bottle moving is adopted with high production capacity and without pauses

- The main electrical appliances, optoelectronic fiber and pneumatic components are all products of imported brands.

 

 

4,Energy efficient effect

- Unique design of bottle unscrambling, bottle washing, filling, stoppling, capping and cap turning multifunctional integrated machine. The production line takes small floor space, so as to greatly reduce the purification space and lower production and purification costs.

- A large number of PLC control systems with mechanical electrical and pneumatic integration are applied during the equipment operation process, so as to improve the stability of the equipment during operation, greatly enhance product qualification rate, realize stepless speed control of the motor and greatly save electric energy when working with the high-efficiency energy-saving frequency converter.

- Parts with frictional movement between them are made of powder metallurgy, engineering plastics, etc. They are resistant to high temperature, abrasion and have good self-lubricating performance, so as to effectively reduce the wear during the moving process and reduce the replacement of wearing parts.

- The equipment has a switching program, and the adjustment of specifications can be realized through adjusting the height of the track, reducing the time for manual adjustment, cleaning and replacement of specifications.

- Low starting current, low starting torque and high power factor over the entire speed range.

 

 

5,Safe, reliable and trustworthy product

- As PLC control systems with mechanical, electrical and pneumatic integration are applied, the operation is safe and reliable with low failure rate and very low running and maintenance costs.

- With overload automatic protection function, it will automatically shut down when any fault occurs. The faults of electrical parts are displayed on the man-machine interface.

- The equipment has a switching program, which can realize the adjustment of specifications, avoid artificially polluting the operating environment of the equipment and effectively realize aseptic operation in the isolated warehouse.

- Linear actions do not disturb the 100-grade laminar flow protection wind and effectively realize the aseptic production process.

- Elimination of fallen bottles, no filling in case of no bottle shutdown protection in case of no bottle, waiting for automatic starting, no outer cap feeding in case of no inner stopple, elimination of nonconforming products, weighing and detecting, counting and automatic interlocking protection of adjacent devices.

 

6 Main technical parameters

 

Product model	XHL-DXYG2/1/1	XHL-DXYG4/2/2	XHL-DXYG4/8/8	XHL-DXYG6/12/12	XHL-DXYG8/12/12	XHL-DXYG12/18/18
Stable production capacity ( bottles/minute)	50-60	90-100	100-130	130-160	160-200	300-330
Bottle moving mode	intermittent type		continuous rotary type
Number of filling heads	2	4	4	6	8	12
Number of cap pressing heads	1	2	8	12	12	18
Number of cap turning heads	1	2	8	12	12	18
Filling accuracy	≤±0.5%
Stoppling rate	≥99.9%
Capping rate	≥99.9%
Pass rate	≥99.9%
Compressed air pressure	0.4-0.6Mpa
Total power	≤3kw		≤6kw
Power supply	220v/380v  50/60hz
Weight	1200kg	2000kg	1500kg	2000kg	2500kg	3000kg