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.

The Newman CTE350 Labelling Machine

A fully automatic labelling system which applies self-adhesive tamper-evident labels (security labels) to erected cartons.

The CTE350 is a fully automatic labelling system which applies self-adhesive tamper-evident and hologram labels (security labels) to erected cartons. Designed primarily for the pharmaceutical industry where line space is at a premium, the compact design permits easy integration into existing packing lines.

The CTE350 incorporates full Newman ‘validation-friendly’ specification.

At the infeed, cartons are separated, held under a top belt and transported past two stepper motor-driven label stations. Labels are dispensed on to the overhanging vertical faces of the carton and applied with a roller.

Airplane and reverse tuck formats can be accommodated. Cartons proceed to the sensing station where sensors detect label presence prior to wipe down. 

Both labels must be present for a carton to be accepted; if not, it is ejected into a secure reject area.

Features

  • Compact
  • GMP Design
  • Stainless steel finish
  • In Process Control
  • Stepper motor drive for label web
  • “Positive accept” security system
  • Automatic critical device checking
  • Reject verification
  • Product and reject counter package
  • All adjustments scaled for repeatability
  • No change parts
  • Validation Documentation Package

For more information and pricing please contact us 800-829-5741.

Bahnson’s ES2000 Reach-In product line

The ES2000 reach-in stability chambers is provided in four standard sizes, ranging from 12 to 144 cubic feet, each offering a wide variety of temperature, humidity, and light (photostability) capabilities.

Our typical reach-in chamber uses include ICH stability, shelf life studies, photostability (ICH Q1B Option 1 and 2), incubators, plant growth, tissue culture storage, freeze-thaw, blast freezing, and other product testing and/or stability storage.

Chambers can also be designed to meet classified storage requirements (Class 1 Div 2), HEPA filtered cleanroom standards (Class 100-10,000), cycling/stress test requirements, or other special design requirements on request.

BES offers a range of environmental test and stability chambers designed for high demand testing, processing, conditioning, or growth applications.

The ES2000 product line includes six standard models. Standard temperature capabilities range from 2° C to 70° C, with controlled humidification, lighting and CO2 available.

We can provide complete performance qualifications on our and competitive chambers. Our staff writes your IQ, OQ, and PQ Protocols and trained technicians perform field tests and validation qualification tests.

Calibrations and test equipment used during qualifications are NIST traceable and are provided as part of your validation services.

Comprehensive reports are written to summarize your data for quick reference by your company and for regulatory agencies.

Please contact a member of our sales department for more details on how we can accommodate your testing needs.

Contact our product specialists to acquire further information.

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.

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.

ST-120S Industrial Cap Torque Tester

The ST-120S features a servo drive control, infinite chuck rotation, quick-change tooling, a color touchscreen interface, and faster cycle times.

The corrosion-resistant stainless steel head enclosure and anodized aluminum frame construction make the ST-120S ideally suited for the most demanding applications, such as testing closure torque at Carbonated Soda Drink (CSD), juice, bleach bottling operations as well as cleanroom environments.

The unit is equipped with anti-bridging, anti-tie down anti-repeat dual actuation safety start switches, but for maximum operator safety, the ST-120S can be also equipped with a full machine guard.

Features

  • Real-time, automatic display
  • NIST traceable calibration procedure
  • Strain gauge transducer technology
  • Automatic container clamping and closure gripping
  • Adjustable torque application speed
  • Counterbalance system for height adjustment
  • Infinite rotation (SERVO)
  • Encoder to measure the angular degree of rotation
  • Heavy-duty components

Testing Capabilities

  • Applied Torque: The ST-120 can be used as a benchtop capper, tightening the cap to a customer-defined setpoint.
  • Release Torque: The ST-120 is designed to accurately measure the release (thread break) torque of a cap.
  • Peak/Transient Torque: The standard ST-120 can measure and display the Applied or Release Peak in a torque testing cycle, however with optional hardware upgrades it is also possible to measure certain torque transients such as the engagement torque of a CR closure system or the peak of the bridge break torque of a Tamper Evident Band.
  • Container/Closure Fatigue: By allowing the ST-120 to apply and release the cap a number of times, it is possible to evaluate the effect of fatigue on the torque retention and seal quality of the closure and seal.
  • Release and Re-apply Torque: When packaging expensive products it is often required to return the tested container to the packaging line. By automatically re-applying the torque to the operator defined setpoint it is possible to save the product.
  • Topload Force (optional): This feature allows the monitoring and control of topload force. When testing child resistant caps or other closures requiring topload adjustment this feature allows the evaluation of topload force in the function of rotation and torque.

Contact Life Scientific, Inc. for more information on this equipment.

How does Vetromeccanica’s Vacuum Conveying Work?

Vacuum Conveying is the process of moving bulk dry materials, such as powders, from place to place within a factory using suction. The material is transferred in a network of tubing from the pickup point or source to the customers’ process. Most Vacuum Conveying System transfer product based on a timed interval to the vacuum receiver. At the end of the timed sequence, the discharge valve can open and the material conveyed can discharge into the process. 

There are two types of vacuum conveying. Dilute phase conveying and Dense phase conveying. 

  • Dilute Phase Conveying the material is entrained in the air stream and the is an almost equal part of air and product. This method is excellent for conveying almost any type of powder-like sugar or flour. 
  • Dense Phase Vacuum Conveying the material is transferred in slugs within the convey tubing. The material moves slower then dilute phase conveying and is an excellent choice for a friable product or a blend of powders. 

Vetrommecanica’s conveying systems differ from others because they increase the real plant efficiency. They are a major player in more than 70 Countries thanks to the care and attentiveness to details, capability to offer a 360° all-rounded service, and to their extremely skilled customer-care department.

Learn more about the conveyance solutions we are currently offering by giving us a call at 800-829-5741

Onion Skin Ampoule Filling and Sealing

A manufacturer of drug and explosive detection equipment for law enforcement, hazmat teams and educational systems.

Cozzoli were approached about a need for filling onion skin style ampoules. These ampoules would be part of a mobile detection system, where after swabbing a potentially contaminated area, the swab is inserted into the pouch and the ampoules are crushed. The chemical inside of the ampoule mixes with the swab and will detect if any drug or explosive residue is present.

This application would require the ampoule to be filled with a small and very precise amount of liquid, then flame sealed.

This was a perfect application for our FPS series ampoule filling and sealing MonoBlock. The application required the filling of 6.70mm x 60mm onion skin tubes with .10 mL -.40 mL of liquid. This would have to be done at a production rate of 45 -50 ampoules per minute. Due to these requirements, the FPS1-OS-SS was chosen for the job.

Our FPS series monoblock fills and seals a variety of ampoule shapes and sizes, at speeds of 15-120 ampoules per minute and a fill accuracy of +/- .5%.

With the fill volume requirements being so small, a peristaltic pump was added in order to feed the liquid into the machine. A peristaltic pump is typically used for very precise filling applications, as well as applications where the liquid is clean/sterile and cannot come into contact with any exposed pump components.

For more information on how we can help with your ampoule filling applications, contact us at 800-829-5741

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