The Counting Unit

TRACEABILITY OF PRODUCTS IN THE PHARMACEUTICAL INDUSTRY

Manual counting processes are often very error-prone and are no longer permitted in many areas. The balancing unit for the pharmaceutical industry enables automatic, piece-precise counting of vials, ampoules or syringes.

It is used to balance products during production and to collect samples when performing a media fill.
All counting processes are documented (digitally and in paper form).

Individual processes enable the printing of container cards, the comparison of counting results and locking in the event of an error. Intuitive operator guidance guarantees an optimal workflow. Counting results are visualized clearly and understandably. With a processing speed of approx. 180 trays per hour, an ideal process time is achieved.

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Labels for trays and pallets can be printed automatically with all the necessary batch and count information.
By using 2D matrix or barcodes, the most important information can be captured directly from the label using a code scanner.

Mediafill processes are documented with interim and final reports in compliance with the audit.
The counted batches are managed directly in databases and can be called up at any time with all information. Incorrect counting is eliminated by the automatic balancing station. The traceability of your processes is raised to a completely new level.

The integrated camera system enables smooth and easy teaching of new formats. Even objects that are difficult to see optically can be counted without errors.

100% adjustment of vials and ampoules in trays

The first counting unit on the market that can be operated inline with other machines without slowing them down.

No disadvantages due to external factors such as ambient lighting, shadows by operators or the like.

No worst case format recognizable. (Not even with gray caps in gray trays)

Vials and vials can be counted regardless of their size, the size and color of the lid, and the size and color of the tray.

8x different cylinder ampoules
2R, 6R, 10R, 10R high, 30R, 5ml, 10ml

8x different Vials
1,5ml, 1,7ml, 3ml

5x Tray Colors

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16 cap colors

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6x packaging sizes

Advantages of process optimization through automation and digitization

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The counting process

LIGHT BARRIER 2 INTERRUPTED
It is checked whether a tray / tub is already in the checked position. In this case, the count is started immediately without the motors being activated.

LIGHT BARRIER 1 INTERRUPTED
It is checked whether a tray / tub has already been pushed to the first light barrier. If the light barrier is occupied, the motor is activated.

COUNTING JOB ANALYSISThe counting job starts automatically. The tray / tub ID is read (if available) and the camera job for counting is carried out. All data is then transferred to the OPC UA server.

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WAIT FOR CONFIRMATION BY SADG
The operator must confirm the counting result in the SADG interface. He has the following options: OK: Tray / Tub moves out of the system (production direction) Abort: Tray / Tub moves out of the system (Inbound direction)

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EXIT THE TRAY
Motor is switched on Depending on the driving style or operator feedback, the tray / tub is moved to the right or left of the system.

Tray / Tub turns right:
Motor remains switched on until light barrier 1 is no longer occupied or a timeout occurs. This timeout is not an error.

Tray / Tub moves to the left:
Motor remains switched on until light barrier 2 is no longer occupied or a timeout occurs. This timeout is not an error.

MOBILITY AND EASY TO USE

The height of the counting units can be set electronically, so that it is possible to easily count the counter into existing ones Insert production lines. With a simple docking mechanism, it can be connected to almost any other machine. Trays can thus be easily pushed from system to system. Lifting and carrying is therefore not necessary.
HSE: In addition, the monitor arm can be rotated and adjusted in height. Each operator can individually adjust the working position. In the case of left-handers or changing operating situations, the label printer can be turned and the system can be operated from the other side.
Mobility: The transport unit can be moved anywhere in a building using transport rollers.

GMP COMPLIANCE

The main task of quality control units in the pharmaceutical industry is the testing of active pharmaceutical ingredients, auxiliaries and packaging materials. The main focuses of GMP are above all the requirements for hygiene, for the premises, for the equipment, for documentation and controls. It must therefore be ensured that the necessary checks are carried out in the incoming goods department and that the materials are only released when their quality has been assessed as satisfactory. The GMP rules are laid down in national and international regulations.

PAPERLESS

Nowadays, manual and error-prone processes no longer need to be done for goods receipt or inspection on the production line. Paper delivery notes and counting notes no longer have to be transferred to the system, but are simply recorded with the ADOMO system from MODI and the information is made available to the customer system.

TIME SAVING

If all ampoules or trays had to be counted manually, one can imagine that this is very time-consuming and prone to errors. With the balancing unit, vials and ampoules in trays are counted within seconds and registered in the customer system. The reduction of manual and therefore error-prone activities is the biggest advantage of such a system.

Ergonomic

The table is height adjustable and can therefore be quickly and easily integrated into any production line. The monitor and the suspension arm can also be rotated and adjusted in height to achieve an ergonomic position for every operator. In the case of left-handers or changing operating situations, the label printer can be turned and the system can be operated from the other side.

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