INTERNSHIP REPORT

ON

“BLISTER QUICK SERVO”

REPORT DONE BY,

KARTHIK CHAKILAM

MECHANICAL ENGINEERING

GITAM UNIVERSITY,

VISAKHAPATNAM,

2013-2017

QUALITY OBJECTIVES

BLISTER QUICK SERVO

TO TRAIN THE YOUTH IN EMPLOYABLE SKILLSTHROUGH HOLISTIC TRAINING.

TO INCLUCATE THE CULTURE “PRODUCE WHILE LEARNING AND LEARN WHILE PRODUCING”.

TO KEEP PACE WITH TECHNOGICAL DEVELOPMENMTS

TO SUPPORT INDUSTRIES AND INSTITUTES IN DISSIMINATION OF TECHNICAL KNOWLEDGE AND SKILLS.

TO EXPAND THE SCOPE OF TRAINING NATIONALLY AND INTERNATIONALLY

SYNOPSIS

BQS (BLISTER QUICK SERVO) is the machines which provide

perfect and fast solution for all the blister packaging solutions. This machine was designed

and built in the year 2000, and first machine sold in 2001, under the observation of many

great employees of ACG PAMPAC from then on machine took its huge growth of sales

all over the world and became one of the best selling machine of the company.

This machine has 5 servo motors for main cam, punching station, pulling station,

feeding drum ,and printing station, This machine features flat forming, flat sealing which

results in fast actuation is suitable to hold the foil with thickness ranging from 200 to 300

microns only.

Synchronization of different movements in blister packing can be achieved by

mechanically linking the movement of the different axes. Thus, it reduces changeover

time.

GITAM UNIVERSITY 2

BLISTER QUICK SERVO

Table of Contents

1.0 COMPANY PROFILE

2.0 MECHATRONICS

3.0 WHAT IS MECHATRONICS?

4.0 SCOPE OF MECHATRONICS

5.0 TECHNICAL

6.0 ACKNOWLEDGEMENT

7.0 PROFILE

8.0 SPECIFICATIONS

8.1 MACHINE LAYOUT

8.2 MACHINE PERFORMANCE

8.3 FOILS SPECIFICATIONS

8.4 UTILITIES

9.0 STANDARD FEATURES

10.0 OPTIONAL FEATURES

11.0 SAFETY FEATURES

12.0 MACHINE LIMITATIONS

13.0 FUNCTIONAL GROUPS

GITAM UNIVERSITY 3

BLISTER QUICK SERVO

13.1 FORMING FILM REEL MOUNT

13.2 FORMING FILM SPLICING UNIT

13.3 WEB GUIDE AND FILM CLEANING UNIT

13.4 FORMING FILM UNWINDING UNIT

13.5 HEATING STATION

13.6 FORMING STATION

13.7 FORMING FILM JOINT SCANNER

13.8 FEEDING SYSTEMS

13.9 LIDDING FOIL REEL MOUNT

13.10 PRINT REGISTRATION CONTROL

13.11 SEALING STATION

13.12 COOLING STATION

13.13 PULLING STATION

13.14 LOOP SENSOR

13.15 EMBOSSING STATION

13.16 PERFORATION STATION

13.17 WEB GUIDE ROLLER

13.18 INDEXING STATION

13.19 PUNCHING STATION

13.20 BLISTER PICK UP UNIT

14.0 ATTACHMENTS (OPTIONS)

GITAM UNIVERSITY 4

BLISTER QUICK SERVO

14.1 COLD FORMING CYLINDER

14.2 CONTACT OVERPRINTING UNIT

14.3 CAMERA SYSTEM

14.4 WIPER BRUSH

14.5 PRE-ASSISTING FOR SEALING

15.0 INTERLOCKS / ALARMS

16.0 MAJOR BOUGHT OUT PARTS

17.0 CONCLUSION

COMPANY PROFILE

ACG Pampac, a member of ACG Worldwide, manufactures highly efficient and cost-effective blister packing, cartoning machines and allied packaging solutions for a variety of industries. 

Justifying a high output to cost ratio, ACG Pampac's blister packing range is reliable and flexible with a single working drum, a twin-track possibility and easily upgradable mechanics to aid enhanced output and levels of automation. High speed machines for PVC and Alu-Alu blisters also form a part of the versatile portfolio in blister packing. 

The cartoning range has semi-automatic and fully automatic, vertical and horizontal machines. Some of these run in continuous motion making them suitable for non-rigid products, small batch quantities, multi-line packaging, and products that are difficult to pack, like unit packs. 

GITAM UNIVERSITY 5

BLISTER QUICK SERVO

BQS“BLISTER QUICK SERVO”

Flat Forming, Flat Sealing, Blister Packing Machining

8.0 TECHNICAL SPECIFICATIONS

GITAM UNIVERSITY 6

BLISTER QUICK SERVO

8.1 MACHINE LAYOUT, DIMENSIONS AND WEIGHT

Machine Layout parameters

Parameter Specification

GITAM UNIVERSITY 7

BLISTER QUICK SERVO

Length 4530mm

Width 2580mm (doors open)2380mm

Machine weight (net)4200 kg (approx.)5100 kg (approx.)

8.2 MACHINE PERFORMANCE

Parameter SpecificationForming area Maximum 240 (width) X 180 (Advance)

Forming depthUp to 12 mm for PVC foil (thermoforming)

Up to 9 mm for ALU foil (Cold forming)

Forming cyclesUp to 40 cycles per minute for thermo foils

Up to 35 cycles per minute for cold foils

Forming speed Up to 7.2 meters per minute

Noise level 80 dB at 1 meter

Punching cycles Maximum 180 cycles per minute

Percentage rejection Up to 0.5% for standard DS

No. of Tracks Single, Twin, Three tracks

8.3 FOILS SPECIFICATIONS

Parameter SpecificationForming film

Material

• PVC• PVC/PVdC• ACLAR,• Triplex (PVC/PE/PVdC),• Cold form foil (Alu)

Thickness Maximum 350 micronMinimum 200 micron

Width Maximum 252 mm

Roll diameter (Max) 400 mm

Lidding foil

Material• Push through (alu)• Peel able (Paper)• Child Resistant (CR)

Thickness • 20 to 25 micron aluminium foil

GITAM UNIVERSITY 8

BLISTER QUICK SERVO

• Standard paper & CR foilsWidth Maximum 246 mm

Roll diameter Maximum 250 mm

8.4 UTILITIES

Parameter SpecificationSupply voltage 3 Phase, 415 / 380 / 220 V AC, ±10%

Supply Frequency 50/60 Hz ± 2%

Connected load 19 kW

Air pressure Minimum 6 bars, Moisture and oil free air

Air consumption 30 CFM @ 6 bars with Air venturi

Cooling water temperature18 to 200C for PVC

8 to 100C for PVDC

Cooling water flow rate 14 to 16 liters/minute

Cooling capacity 9000 Kcal/hour

Vacuum requirement 26 to 28" of Hg

9.0 STANDARD FEATURES

Output up to 320 blisters/min in twin track (for blister size 118X40mm). Large format area of 240 X 180 (indexing) mm. Plug assisted forming for deep cavity & PVC/Aclar foil Edge to Edge Punching – Zero wastage in web travel direction.

GITAM UNIVERSITY 9

BLISTER QUICK SERVO

Full 3D changeover – 65 minutes including setting of format part. Hydraulic clamping in forming & sealing station. Two forming film reel mount. Provision with servo drive unit available on request for fitment of online printers

for aluminium foil printing (e.g. HAPA, Gottscho etc.). Format specific guide roller to reduce blister curling Cartridge type heaters for easy & fast repairs Long life, FDA compliant, surface coating on most of the parts Maintenance free gear boxes for major stations

10.0 OPTIONAL FEATURES

Embossing Overprinting unit. Perforation. Aluminium forming and feeding facility. Plug assisted forming of thermoformable films for low draft angle formats. SCADA / 21 CFR Part 11 compliance software and hardware on request. Pin hole detector for Aluminium/cold forming film. Camera based blister inspection system for Print verification, Pharma code on

lidding foil, missing or broken tablet etc Tablet recovery system. Pre assisting for sealing Guarding: Polycarbonate / Acrylic ADU (Dust extraction unit) Set of Embossing letters Brush Box (Main unit) Spares (Recommended) Conveyor & line cartoning parts to integrate to cartoner Tablet Elevator Validation documents Water Chiller Format parts trolley

11.0 SAFETY FEATURES

Two Emergency stop switches provided, one at HMI and another at punching station.

All moving parts covered with guarding and interlocked. Safety switches provided to guards / doors in Operator accessible areas. Warning labels provided as required by EU standard. Password protected user levels.

12.0 MACHINE LIMITATIONS GITAM UNIVERSITY 10

BLISTER QUICK SERVO

Individual cavity length in direction of web travel is about 38mm maximum. Forming film thickness range from 200 to 350 microns only. (Thermoforming). Lidding foil thickness range from 20 to 70 microns only. Draw off length of the machine ranges from 99mm to 180mm. Dot type sealing only.

13.0 FUNCTIONAL GROUPS

13.1 FORMING FILM REEL MOUNT

GITAM UNIVERSITY 11

BLISTER QUICK SERVO

About:

400mm diameter reel can be mounted. Foil break check sensor continuously monitors the forming film. Additional reel mounting provided to reduce downtime. Quick setting with rotating knob.

13.2 FORMING FILM SPLICING UNIT

GITAM UNIVERSITY 12

BLISTER QUICK SERVO

About: Vacuum hold as an option for locking film during splicing, Control from HMI.

13.3 WEB GUIDE AND FILM CLEANING UNIT

About:

Web guide rings adjustable as per film width, tool less adjustment. Spring loaded film cleaning plate cleans film before heating and forming. Hard anodized parts help smooth travelling.

13.4 FORMING FILM UNWINDING UNIT

GITAM UNIVERSITY 13

BLISTER QUICK SERVO

About:

Unwinding with AC Induction motor, controlled by inductive sensor. Intermittent unwinding. PU coated unwinding roller for enhanced gripping. Hard anodized pressure roller.

13.5 HEATING STATION

GITAM UNIVERSITY 14

BLISTER QUICK SERVO

About:

Teflon coated heating plates. Cartridge heaters in a plate facilitate easy, quick maintenance & repairs. Individual cartridge can be replaced. Replacement of plate is not required Low maintenance cost Easy repair & maintenance Higher machine safety since cartridges are CE certified

13.6 FORMING STATION

GITAM UNIVERSITY 15

BLISTER QUICK SERVO

About:

Flat forming, intermittent motion. Forming station with hydraulic clamping. Large forming area, i.e. 240 X 180mm (DOL). Quick changeover of forming parts. Forming of PVC, PVC/PVDC, ACLAR and Aluminium film possible. Special electronic cam profile for smooth operation and low noise.

13.7 FORMING FILM JOINT SCANNER

GITAM UNIVERSITY 16

BLISTER QUICK SERVO

About:

Colour mark sensor to check film joint. Input of this sensor controls feeding of product in the specified area as well as rejection of blisters.

Various colour tapes can be used. Only sensor setting needs to be done.

13.8 FEEDING SYSTEMS

GITAM UNIVERSITY 17

BLISTER QUICK SERVO

About:

Rotary vibrator for good feeding efficiency. Hopper, Linear vibrator and rotary vibrator fully covered. FDA approved product contact parts.

Feeding options: Continuous channel Continuous channel with feeding drum (Cold-forming formats). Spring channel. Spring channel with feeding drum (Cold-forming formats). SS fabricated channel for special tablets. Brush box feeding. Other options as per product to be handled.

13.9 LIDDING FOIL REEL MOUNT

GITAM UNIVERSITY 18

BLISTER QUICK SERVO

About:

250mm diameter reel can be mounted. Foil break check sensor continuously monitors the lidding film. Quick setting with rotating knob. Vacuum splicing unit after lidding foil reel mount as an option.

13.10 PRINT REGISTRATION CONTROL

GITAM UNIVERSITY 19

BLISTER QUICK SERVO

About:

Servo controlled Print Registration Control System. Foil stretching by servo controlled pulling rollers.

13.11 SEALING STATION

GITAM UNIVERSITY 20

BLISTER QUICK SERVO

About:

Dot type sealing only. Electro-less nickel plated bottom sealing plate (Format part). Water cooled bottom sealing plate. Water circuit doesn’t open during changeover: “No water spillage on machine”. Quick changeover of bottom sealing plate, tool less.

13.12 COOLING STATION

GITAM UNIVERSITY 21

BLISTER QUICK SERVO

About:

Hard anodized, water cooled, cooling plate. Large area of cooling plates increases cooling efficiency.

13.13 PULLING STATION

GITAM UNIVERSITY 22

BLISTER QUICK SERVO

About:

1/3rd energy consumption compared earlier pulling drive. Reduced noise level Quick & simple alignment & mounting Reduced maintenance

13.14 LOOP SENSOR

GITAM UNIVERSITY 23

BLISTER QUICK SERVO

About:

Suitable to handle all types of Lidding and Forming foils Ensures “Blister Reject Count” does not change Fool proof– does not allow any mistake while web setting No adjustment required Cost effective

13.15 EMBOSSING STATION

GITAM UNIVERSITY 24

BLISTER QUICK SERVO

About:

Quick changeover of embossing letter holder and counter plate. Hot embossing is possible as an option. Servo drive (from punching station). Max. 64 letters per stroke Letter height 1.59 and 2mm No. of letters per line: 22 No. of lines: 1,2,4

13.16 PERFORATION STATION

GITAM UNIVERSITY 25

BLISTER QUICK SERVO

About:

Quick changeover of perforation tool (Format part). Hot perforation available. Cross, along web travel, perpendicular to web travel is possible.

13.17 WEB GUIDE ROLLER

GITAM UNIVERSITY 26

BLISTER QUICK SERVO

About:

Light weight PVC discs. Easy setting with knobs for setting perforation position.

13.18 INDEXING STATION

GITAM UNIVERSITY 27

BLISTER QUICK SERVO

About:

Hard anodized indexing roller (Format part). Sensor to check “Web jam” in punching. Easy setting of Guide roller setting with knobs.

13.19 PUNCHING STATION

GITAM UNIVERSITY 28

BLISTER QUICK SERVO

About:

Quick changeover of punching tool (Format part). Edge to Edge punching, i.e. Zero wastage in web travel direction.

13.20 BLISTER PICK UP UNIT

Blister dropping at 450, 900, and 1800 possible. (Reject, good blister, good blister overflow)

Vacuum generation by Air venturi. Blister dropping on belt conveyor as an option.

14.0 ATTACHMENTS (OPTIONS)

14.1 COLD FORMING CYLINDER FOR FORMING

GITAM UNIVERSITY 29

BLISTER QUICK SERVO

About:

Pneumatically operated form cylinder to create forming force in Aluminium forming film.

Minimum input air pressure required is 5.5 bars. 30 litters air reservoir provided at back side of the machine for air supply. Plug assisted forming possible for thermoformed foils, if CFF option exists on the

machine.

14.2 CONTACT OVERPRINTING UNIT

GITAM UNIVERSITY 30

BLISTER QUICK SERVO

About:

Servo drive ensures precise control in printing position. Easy setting with knobs. Stereo roller is a format part.

14.3 CAMERA SYSTEM

GITAM UNIVERSITY 31

BLISTER QUICK SERVO

About:

High resolution color camera for Blister Inspection. Inspection of blister from PVC side possible. Pharma code on blister check. All options possible with multiple cameras, Integrated to single CPU. Up to 12 tracks support possible

Base Film Possible: PVC Clear PVC Opaque PVC Colour Alu Foil Aclar Film

GITAM UNIVERSITY 32

BLISTER QUICK SERVO

Types of Product: Multi Products Bi colour Sandwich Printed Capsules (Single & Multi-colour) Printed Tablets White product on White Opaque Film

Defect types: Product missing Different Product Shade Variation Broken Product Object oversize area Object undersize area Particle broken object outside pocket Spots of contrasting colour Chipped Tablet (For coated Tablets) Double Product Different Shape Vertical Tablet Product Outside Cavity Powder in Cavity Hair Extra Particle in cavity Crack with tablet joined Foreign Particle inside cavity Foreign Particle outside cavity Cap Missing Body Missing

14.4 WIPER BRUSH

GITAM UNIVERSITY 33

BLISTER QUICK SERVO

About:

Wiper brush to wipe out excess tablets from the guide plate. Only for PVC / PVDC format parts

14.5 PRE ASSISTING FOR SEALING

GITAM UNIVERSITY 34

BLISTER QUICK SERVO

About:

Pre-heating of CR (Child Resistance) lidding foil before sealing. Independent control panel Verified and validated with Amcor on seal strength of the blister.

15.0 INTERLOCKS / ALARMS

GITAM UNIVERSITY 35

BLISTER QUICK SERVO

Sr. No. Error / Fault message Effect1 Emergency stop console / machine Immediate stop

2 Motor overload Immediate stop

3 Air pressure low Immediate stop

4 Guard open Immediate stop

5 Low water flow, Heaters OFF Home stop

6 Lidding foil end Home stop

7 Forming foil end Home stop

8 Web slipping at punching station Home stop

9 Low temperature Home stop

10 High temperature Home stop

11 Thermocouple open Home stop

12 Thermocouple check Home stop

13 Homing not done Machine will not start

14 Switch ON vacuum Home stop

16.0 MAJOR BOUGHT OUT PARTS

Sr. No. Item Description Make1 PLC Mitsubishi

GITAM UNIVERSITY 36

BLISTER QUICK SERVO

2 HMI Weintek

3 Servo Motors Mitsubishi

4 Drives Mitsubishi

5 Sensors IFM / P & F

6 Switch Gear Telemechanique

7 Bearings SKF, FAG

8 Pneumatics Pneumax

17.0 CONCLUSION

GITAM UNIVERSITY 37