ST-FT1 Chuck Calibrator

Mesa Labs’ new ST-FT1 is a universal handheld torque/force display that, when coupled with the Chuck calibrator adapter, can be used to verify/calibrate chuck capper heads. Cap adapters are easily replaceable to accommodate various chucks.

Possible causes of equipment related torque variation:

  • servo current fluctuation
  • temperature variation related torque fluctuation of a magnetic slip chuck
  • varying chuck speed
  • varying friction between the chuck and the cap OD (slippage)
  • topload force variation

To verify chuck-capper operation, use Mesa’s ST-FT1 chuck calibrator. This is a compact torque testing device for both engineering (FAT of capping equipment, troubleshooting torque issues of existing capping equipment) and production use (individual capper chuck adjustment). With this device, you can prove whether the torque variation is the result of servo current fluctuation (inconsistent application torque), product variation or another variable in the capping process (gripping pressure, topload, etc).

Target applications include but not limited to:

  • OEM/Packaging Engineer testing the performance/repeatability of the torque applied by capper chucks during machine design, factory acceptance testing/validation.
  • Packaging line operator verifying and adjusting capper chucks
  • Packaging Engineer evaluating whether torque variation is caused by the capping equipment or the package.

Contact Life Scientific, Inc today to discover more info regarding this very capable torque tester.

Headspace Gas Analysis: What’s on the Shelf?

Many injectable drugs are sealed into containers (typically glass vials or ampoules) after processing, in protective atmospheres to avoid contact with air that can damage quality & effectiveness. Nobody would like to open a yogurt jar and find fungus or buy medicine and find it has lost its effectiveness due to oxidation.

Here we are identifying two main impacts: Business Impact and GMP (Good Manufacturing Practice) Impact. In the first case, the company can lose business, in the second, it could cause serious illness to people. Different Container Closure Integrity Testing (CCIT) methods can be put in place to avoid the above: Vacuum Decay, Pressure Decay, Force Decay, Lid Deflection, Spark Test and last but not the least Headspace Gas Analysis (HGA).

Pharmaceutical Companies are required to protect their products not only with proper and safe enclosures, but they must also fill the space that surrounds the product (i.e. headspace), with some particular gases (e.g. Nitrogen, Carbon Dioxide) or simply maintain a high level of vacuum inside the enclosure, to avoid contact with oxygen or moisture.

At this point dear reader, I hope you have understood why it is so important to know what’s happening inside the headspace of your container. Headspace Gas Analysis plays an important role among the CCITs. Let’s add some more details.

Two different methods can be used to inspect headspace: destructive and non-destructive methods. In the destructive method, measurement of gas percentage present inside closed package requires the necessity to bring part of its internal atmosphere in contact with a proper sensor (e.g. chemical cell or zirconium oxide for oxygen) to be able to produce electricity proportionally to the gas concentration or use optical fluorescence technologies in case of oxygen detection. Both inspection methods result in package destruction.

Tunable Diode Laser Absorption Spectroscopy (TDLAS) is a non-destructive method, able to measure the concentration of a certain gas in closed container, with a sufficient headspace size to pass through with a laser beam with fairly good transparency to laser light: glass and plastic containers can be inspected as well if these conditions are satisfied. TDLAS is a technology based on laser absorption spectroscopy, wherein the wavelength diode laser is tuned over the absorption line of the gas under test (760 nm for Oxygen, 1854 nm for Moisture, 2000 nm for Carbon Dioxide) and the intensity of the transmitted radiation is measured.

More the gas molecules are present in the head space, less the energy will arrive at the photodiode used to convert light into an electrical signal. The transmitted intensity can be related to the gas concentration by the Beer-Lambert law. It is possible to obtain information related to the gas under test measuring Area and Width of the Absorption Curve.

However, these measurements are unitless, so a Calibration Procedure is necessary to correlate these values to Gas Concentration (%) or Total Pressure (mbarA).

Calibration Procedure is strictly related to the Standards concept. It is possible to apply techniques of modulation in high frequency to further improve the signal-to-noise ratio, ensuring the detection of small variations of signals in front of a wider operating range: WMS (Wavelength Modulation Spectroscopy) and FMS (Frequency Modulation Spectroscopy) are the most common types of modulation techniques. FMS has a higher modulation frequency (some MHz) than WMS (some KHz); a lower laser residual noise is its main advantage; however, the detectable minimum quantity of gas is less dependent on laser residual noise than Etalon Effect for instance.

Furthermore, working at such high frequencies has another drawback: we need to use analog electronic components instead of digital ones thereby renouncing great advantages coming from them.

Now that we have more knowledge of this technology, we could be interested to understand how to take advantage from a non-destructive method.

You can focus on the following comparisons between the standard destructive method and the non-destructive HGA method to draw your own conclusions:

• Standard Methods to measure gas concentration or pressure value are destructive.

The packages can’t be recovered even if we have a conforming test… HGA is a non-destructive measurement method; packages can be recovered after confirming tests.

More valuable the product, more the item is important;

• Standard Methods are slow; they can’t guarantee 100% check of the whole production… HGA is very fast and it can be placed into an in-line process to test 100% of the production.

It is more expensive, but the return of investment covers the overall expenses;

• Standard Methods of Leak Detection don’t find non-conforming packages due to process anomalies if they are properly sealed… HGA finds non-conforming packages even if they are properly sealed; it measures the gas partial pressure in the headspace.

It is important to remember however, that HGA is not a leak detector if the quarantine period is not part of the production process.

I hope you have found some interesting food for thought about these intriguing arguments.

Unit Dose Packaging Manufacturers

The development of single dose packaging has been a breakthrough for unit dose packaging manufacturers. Single dose packaging or unit dose packaging has a variety of applications that can be beneficial for multiple industries.

Hospitals, pharmaceutical companies, and patients have greater control over medication and, additionally, reducing waste. What are the incredible benefits of unit dose packaging and why is it such a revolutionary development in the contract packaging industry?

The following article will detail this and highlight why the unit dose delivery system may be perfect for your product. If you have any more questions about unit dose packaging or would like to speak with our available packaging options and contract filling services, please contact LF of America

About Unit Dose Packaging

The name unit dose packaging refers to the single premeasured unit of a medicine or substance that the packaging holds. By pre-measuring the dose, the possibility of human error is drastically reduced.

Additionally, it makes the application much easier and comfortable for the user. All the materials used by unit dose packaging manufacturers like LF of America are also made of an eco-friendly bioplastic. 

Clinical and hospital settings can benefit greatly from the innovative single dose packaging development. Patients and personnel can enjoy improved application accuracy in addition to exact dose delivery.

Barcodes are placed on each unit that can easily identify each individual dose. In the event that the package is damaged or tampered with in any way, patients and personnel can identify it immediately.

As mentioned above, unit dose packaging reduces waste and is made from fully renewable resources. Unit dose packaging also makes documentation convenient by providing simple electronic documentation capabilities. 

Manufacturers of unit dose packaging provide numerous benefits for patients by having medication pre-measured prior to application. Unit dose packaging is highly versatile and also provides numerous benefits for other industries.

Amongst other applications, single dose packaging can be found in OTC pharmaceutical products, veterinary care, diagnostics, and cosmetics. 

Additional Benefits of Single Dose Packaging

Many health products provide samples for customers to try. Single dose packaging’s size and ability to protect its content makes it perfect for samples. Diagnostic test kits in unit dose containers are able to completely eliminate the possibility of human error while simultaneously improving personnel convenience. 

More forward-thinking businesses have begun discussing how to incorporate this revolutionary development. The convenient size of unit dose packaging and protection can make handing out gel, perfume, lotion, and other samples easier than ever before. 

One of the most recent industries to begin contacting unit dose packaging manufacturers is the CBD industry. Whether its medication, cosmetics, or CBD packaging, single dose packaging provides benefits like no other packaging method before it.

If you are interested in incorporating unit dose packaging for your business, please contact us today. We will gladly assist you and answer any questions you may have. We will also be happy to provide free samples filled with your product. 

Advancing Personal Care Filling

Cozzoli specializes in providing complete filling and capping solutions for all cosmetic, health, beauty aids, and personal care packaging applications.

From automatic fillers with a speed of 200 bpm or a small tabletop unit for lower production, Cozzoli has a range of fillers to fit your needs.

Choose from a variety of personal care filling methods to meet your production goals.

Cozzoli offers inline or rotary filling with piston, peristaltic pump, diaphragm pump or time pressure technology. Our machines handle a broad range of container shapes and fill viscosities from aqueous to heavy creams.

Choose continuous or intermittent motion, stand-alone or monoblock configuration. Every Cozzoli filler provides unmatched ease of container handling and change-over.

These fillers perform with outstanding accuracies of +/- 0.5% or better of fill volumes.

To find more about the Cozzoli cosmetic and personal care solutions please head over to the products section or call our corporate office.

Turn-key integrated solution Case Study

Case Study: when one of the biggest European tuna can producers was losing cans to uneven heat distribution in processing, Fedegari developed a turn-key integrated solution that resulted in 0 rejected cans.

The challenge

Overcoming undesirable temperature fluctuations and overheating, guaranteeing homogeneous heat distribution throughout the load. · Developing a fully integrated solution for treating different tuna can formats, increasing productivity and, consequently, reducing operating costs.

The context

The nutritional quality of the products as well as microbiological and sensory quality are essential factors in the food industry. The thermal processing of canned food is the most important step in the canning procedure1 . Currently, a large quantity of canned goods is rejected during production and has to be destroyed or reprocessed due to inefficient performances of sterilization. This increases the energy consumption and other significant food processing costs. 1 Ibrahim M. Ismail, Alaa Fahmy, Ahmed Azab, Magdy Abadir, and Seif-Eddeen K. Fateen. “Optimizing the sterilization process of canned food using temperature distribution studies”IOSR Journal of Agriculture and Veterinary Science (IOSR-JAVS). For example, overcooking may cause a weight reduction of the product which obligates the manufacturer to complete the cans with additional product in order to comply with the weight indicated on the labelling. Such practices are costly. Sterilization plays a vital role in the food industry as the final product is intended for human consumption. It also represents a critical process since it may influence the quality and safety of the food. In this context, only optimal processing conditions through the proper application of the F-value approach in sterilization allows to optimize the balance between food safety and quality requirements. It assures an appropriate and homogeneous thermal treatment, thus avoiding over- or undercooking, and consequently maintaining the highest standards for uniformity of texture, flavor, and retention of nutrients.

The solution

Process knowledge applied in the development of a fully integrated solution for food preservation and throughput maximization. Fedegari superheated water sterilizers – FOW series (Fig.1) were chosen for improving process performance and throughput. The choice focused on the simplest, most robust and cost-effective solution for sterilizing at a wide range of temperatures with the shortest process time. Fedegari designed an unique, but completely integrated and accurate system. The key for an outstanding performance is the effective control of temperature and F-value which guarantees the highest uniformity to the sterilization process. Control efficiency eliminates errors and rejected loads while operating cost-effectively. The goal was to guarantee the microbiological target along with thermometric performance, through a new process design capable of offering competitive advantage over conventional alternatives. Besides, an additional concern was raised regarding the packaging quality.

The results

Fedegari has supported the customer, one of the biggest European tuna can producers, with in-depth knowledge in sterilization processes, developing a turn-key integrated solution focused on throughput maximization. The customer has increased its productivity at the end of every cycle and the number of rejected cans has been reduced to zero.

FVA/A1 – VERTICAL LAB STERILIZER

The FVA/A1 Vertical Lab Sterilizer combines design with Excellent performances and simplicity of use.

The automatic vertical sterilizer FVA/A1 has been specifically designed and developed to meet the most demanding application requirements in many different sectors, from universities to quality control laboratories in pharma, food or cosmetics industrial sectors.

FVA/A1 autoclave is the perfect solution for highly specialized fields and challenging customers worldwide that demand exclusive, reproducible and validated processes. These sterilizers have been designed with ergonomic features for easy handling and daily use.

The basic version of FVA/A1 can be used for standard processes and is easy to configure, thanks to its conceptual design and modular construction with exclusive optional kits. Please, click on the link “recommended kit” to check out all possible configurations referred to FVA/A1 series.

DESIGN & TECHNICAL FEATURES

FVA/A1 autoclaves are available with three different chamber volumes: 75 liters (FVA2/A1), 140 liters (FVA3/A1) and 188 liters (FVA3/A1 Plus).

FVA/A1 lab sterilizers are equipped with AISI 316L stainless steel chamber and lid with automatic independent operation and control. The access to the technical area is assured by a wide front door with a special safety lock for easy maintenance.

The exclusive horizontal swiveling lid has a patented seal with a compressed air system for perfect airtight, safety and easy maintenance.

An internal heat exchanger, made of AISI 316L stainless steel and a fan for the rapid cooling system can be integrated in the lid. An internal heat exchanger, made of AISI 316L stainless steel and a fan for rapid cooling system can be integrated in the lid. The DCS Plus 10 process controller allows fully programmability: 30 cycles easy to customize in a multi-user environment and an interface for remote monitoring via Ethernet protocol.

The DCS Plus 10 process controller allows fully programmability: 30 cycles easy to customize in a multi-user environment and an interface for remote monitoring via Ethernet protocol. The operating software is fully validated and documented.

KEY BENEFITS

  • Satisfies the most rigid requirements of safety and quality according to international standards.
  • New materials providing chemical inert insulation and both thermal and acoustic: smoother, quieter and safer operations.
  • Energy-saving system.
  • Functional and attractive design.
  • High level of programming and control versatility.
  • Innovative and unique modular design.
  • Ideal positioning of operator panel and printer.
  • Optimized loading height from floor.

Want to know more about our sterilizer product selection, please give us a call and we’ll schedule an introductory conference.

FOW – SUPERHEATED WATER STERILIZER

FOW water cascade sterilizers are able to perform counterpressure sterilization through superheated water.

In compliance with cGMP and FDA standards for LVP products, FOW autoclaves are suitable for treating loads in containers that may be deformed due to the difference in pressure between the chamber and the container itself.

Where the product is liable to separation or for accelerating thermal transition phases, the whole load can be rotated during the entire sterilization process.

  • Process optimization: The process is faster than the air-steam sterilization process. FOW is also an ideal sterilizer for <105 °C processing.

Wet loads can be overcome using an automated drying extension with the installation of specific drying solutions downstream of the sterilization chamber.

  • Easy validation & integrationThema4 process controller is pre-validated according to GAMP5 and in compliance with 21 CFR Part 11, thus resulting in shortest qualification time and minimizing project risks. An open system architecture that can be integrated with SCADA system and other Fedegari machines.
  • Highest productivity: Fedegari R&D laboratory is available to develop the best treatment solution for your specific needs. We run tests with different loads and requirements.

TECHNICAL FEATURES

  • FOW superheated water sterilizer is equipped with AISI 316Ti (AISI 316L upon request) stainless steel chamber.
  • Besides the standard versions from 830 to 14.800 liters, the loading capacity is fully customizable according to customer needs.
  • Chamber internal surface electropolished with a roughness Ra <0,4 μm.
  • One or two doors with vertical or hinged opening systems to cope with available space in the smartest possible way.
  • 5 RTD PT100 probes for temperature control (2 fixed – in the filter and discharge – and 3 flexible for the load).
  • Automatic sterilization of the air filter with a fixed RTD PT100 temperature probe.
  • 2 validation ports.
  • Fedegari exclusive patented door gaskets assure 100% tightness.
  • Piping and valves in AISI 316L stainless steel.

APPLICATION FIELDS

  • Sterilization of parenteral solutions, liquids in sealed containers not deformable (eg. glass vials) and liquids in heat-sensitive sealed containers (eg. plastic bags or bottles).
  • Terminal sterilization of prefilled syringes (PFS).

SPECIAL APPLICATIONS

ROTATING LOAD

The load is held in rotation thanks to a special rotating drum inside the chamber. The rotation drum has a magnetic coupling and is adjustable in speed, the direction of rotation and intermittently. This system finds application in the treatment of suspensions and emulsions and ensures better performance of the tightness tests for ampoules under vacuum and more homogeneous heat transmission in the load.

VIDEO

COMPLIANT TO

  • ISO Standard: 9001:2015, 13485:2016
  • European directives: 2014/68/EU – Pressure Equipment Device (PED), 2006/42/EC – Safety of machinery, 2014/30/EU – Electromagnetic compatibility, 2014/35/EU – Low-voltage device, 2007/47/EC – Medical device
  • European standard: EN ISO 12100, EN ISO 13857, EN ISO 13849-1 EN 55001, EN 61000-4-2, EN 61000-4-4, EN 61000-6-2, EN 61000-6-4, EN 60204-1
  • ASME: Stamp R, Stamp S, Stamp U
  • FDA
  • GMP

Want to know more about our certifications? Please visit the dedicated section or do not hesitate to contact us.

Filling and Packaging Line for Flavoring

Recently, Cozzoli was approached by this customer who was looking to fill gallon-sized containers of liquid flavoring. This was to be a complete line that would incorporate filling, capping, labeling and case packing. Because of the high alcohol content of what was being filled, the filling and capping sections needed to also be explosion-proof.

With the required speed of 20 containers per minute and the containers being clear, it was decided that a 10-head In-Line Fill-To-Level and our Versacapper were the best machines for this application. By using a fill-to-level machine, the liquid in each container would appear to be visually identical. If a volumetric filler was used instead, the volume of each container would be accurate, but due to slight variations in the containers, the visual levels of the liquid could appear higher or lower.

After being capped, the containers would then be moved to another room, via conveyor, where they will be labeled and eventually packed into boxes.

For the labeling and case packing sections of this line, we reached out to our partners at ID Technology and EpsonThe challenge for these areas was that the customer wanted the labels to be print-on-demand. Rather than having the labels feed off of a role, which is the typical application, they needed to be fed directly from the printer to the labeler.

The biggest challenge of integrating the printer with the labeler is that the printer backs up about 12” every time it begins to print. To combat this issue, we used a loose-loop system that uses sensors to monitor the status of the printer and labels.

3 sensors were added into the loose-loop system. The lowest sensor monitors the loose loop to stop the printer when enough labels have been printed.  The middle sensor tells the printer to produce more labels.  The top sensor signals out-of-labels and stops the applicator until more are available. By using this loose-loop system we successfully integrated the printer with the labeler.

Finally, after labeling, the containers are then moved to a table where they are manually packed into boxes and fed through a case packer, which automatically closes, tapes and applies a label to the box.

For more information on how we can help with your complete filling line applications, contact our offices at 800-829-5741

Still time to Revamp Your old Bonfiglioli Engineering Machine

Your old machinery can be upgraded with the latest generation technology to increase machine life and achieve higher performance in terms of productivity, include remote access & increase autonomy of maintenance; all of this with no downtime?

Bonfiglioli Engineering, the worldwide leader in quality control solutions, continuously supports its clients to update their equipment with the most advanced solutions available in the field: UPGRADE III.

UPGRADE III is the substitution of all obsolete or phased out parts of the machine, for both hardware & software, with new latest generation material that is readily available in the market, including microprocessor, PLC, UPGRADE III Invertor and electrical board.

UPGRADE III offers many new features designed to improve functionality, accessibility, and reporting. Here are the reasons why you should upgrade your machinery:

  • LONGER MACHINE LIFE
  • REDUCED COSTS
  • NO DOWNTIME
  • AUTONOMY IN MAINTENANCE
  • REMOTE ACCESS
  • INDUSTRY 4.0 SYSTEM COMPLIANCY

Customized maintenance contracts complete with worldwide dedicated technical services are also available to meet the specific customer’s requirements.

Discover the solution most suitable for you!

Contact us to receive your personal quotation: 800-829-5741

Solutions for Contract Packaging and Filling Companies

Contract packaging companies provide many businesses with the resources they need to succeed. Being able to deliver high-quality products in reliable packaging that is as practical as it is cost-effective is one of the greatest advantages setting many pharmaceutical, cosmetics, and familiar businesses apart from their competition.

What makes LF of America among the top contract packaging companies in the USA is our commitment to each of our prospective clients. Using state-of-the-art contract packaging and filling equipment along with an exceptionally high standard of quality, our clients can trust that we handle every one of the products we handle with the same level of care we would if it were our own.

If you’re looking for contract packaging and filling companies that you can depend on for ongoing reliability, here’s how LF of America can help.

Contract Packaging Services

Our available contract packaging options extend far beyond the unique containers we manufacture. The diverse variety of innovative packaging options we carry enables clients to make the most of the products they provide. In addition, it helps businesses show their customers that they care just as much about the consumer’s use of the products as they do about the products themselves.

We manufacture different packaging options that include unit dose packaging, wand tubes, bottles with droppers, dual chamber bottles, enema containers, vaginal containers, and the specially designed Bellows Bottles. Each of these is available in different options to ensure they are suitable for the unique applications associated with every product they contain. We also provide custom packaging manufacturing services to further meet the more specialized needs of specific clients.

Contract Filling Services

Our in-house contract filling services are a cost-effective option for companies within the pharmaceutical, cosmetics, veterinary care, diagnostics, and familiar industries. We are capable of safely filling liquids in most liquid viscosities, including liquids, gels, creams, and even powders.

Moreover, as turnkey contract packaging partners, we are able to fulfill production demands from start to finish. Our turnkey services are from formulation to batching, packaging selection, and filling, all delivered by one convenient source. We even carry contract filling machines for sale that give our clients the chance to introduce their very own in-house filling solution.

End Your Search For Contract Packaging Companies

If you’re searching for contract packaging companies and are unsure which choice is the best option, we can help. LF of America is proud to be the US-based member of the Lameplast Group, a worldwide leader in contract packaging.

We perform all our contract packaging and filling services in-house and utilize an ISO-8 cleanroom to guarantee safety and quality control. Contact us to get a free quote for any of our contract packaging and filling services or to learn more about what makes us your perfect packaging partners call 800-829-5741.

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