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Home > FillPro Technology > Applications & Case Histories


Applications & Case Histories

CASE 1:

THE CHALLENGES

  • Sticky and moist powder -with very poor flowability
  • Hazardous material, corrosive and combustible
  • Very accurate net weight fills over a very broad range of weights were required
  • High production rates were required

THE SOLUTION

A horizontal Auger was chosen as the basic feed mechanism for several reasons. An auger could feed the sticky material, and could be controlled by a servo motor for the very tight tolerances. Two sizes of augers on different multiple heads were used. A small auger for the small range and a large auger for the higher range and multiple fill head assemblies to meet the production rates. The large auger and large weigh-pan are shown with the auger shroud removed in figure 1.

hazardous material fill solution using horizontal auger
FIGURE 1 (Click to Enlarge)

The small size auger with shroud installed and the small weigh-pan are shown in figure 2.

auger feeder, shroud, weigh-pan
FIGURE 2 (Click to Enlarge)

The material required agitation from a hopper stirrer to move it into the flights of the auger. This is shown in figure 3.

hopper stirrer
FIGURE 3 (Click to Enlarge)

Multiple fill heads of both large and small augers were used to meet the high production rates. The system could produce and verify the weight of 100% in tolerance fills every 1.6 seconds across the range of 5 grams to 400 grams. Each fill was within a tolerance of ½%. Out of tolerance fills were rejected so only good fills were delivered to the production process. The multiple heads are shown in figure 4.

explosive materials fill solution
FIGURE 4 (Click to Enlarge)

This system was built from FillPro standard products and accessories to the NFPA requirements for explosive hazards for Class 2, Div 1 circumstances.

CASE 2:

THE CHALLENGES

  • To accurately fill bags being made on a horizontal form, fill, and seal machine
  • Multiple fill materials used in different combinations at different times, some pelletized in cubes, some in granular, some in powder form.
  • Requirements to both count and weigh the pelletized fills
  • Common discharge point
  • Explosive hazard materials
  • Very precise tolerances with 100 % net-weight verification coupled with a separate redundant final checkweigh scale and accept/reject mechanism
  • Very high production rates

THE SOLUTION

A multiple head and multiple concept feed mechanism was utilized for several reasons. The granular/powder materials were fed by a conical hopper and vibratory feeder. The pelletized cubes which had to be counted and weighed were fed from a conical hopper into a feeder bowl, and from there into the counting and weighing mechanism. The feed for the pellets is shown in figure 1.

pellet feeder mechanism
FIGURE 1
  (Click to Enlarge)

The hoppers/feeders for different powders are shown in figure 2.

powder hoppers and feeders
FIGURE 2 (Click to Enlarge)

The fill system for the multiple materials and common delivery point is shown in Figure 3 as integrated into the form, fill, and seal machine. It should be noted that changeover for different product configurations can be done quickly without tools. The system could deliver 100 % good fills including different combinations of materials at a rate of 3-4 seconds over a range of 15-500 grams at better than 1% tolerance. All fills are net weight checked and the cycle time includes reject of any out-of-tolerance fills. This system was built from FillPro standard products and accessories to the NFPA requirements for explosive hazards for Class 2, Div 1 environments.

integrated powder/pellet/granular fill system
FIGURE 3 (Click to Enlarge)

CASE 3:

THE CHALLENGES

  • Multiple fill weights of difficult-to-feed pure drug antibiotic
  • Dusty powder
  • Automated vial handling required for low labor content and high throughput
  • Clean-room application
  • Very precise tolerances with 100 % net-weight verification
  • Very high production rates

THE SOLUTION

A MONOBLOC multiple head Model 7000 Top Fill system with an automatic vial handler is utilized as the base system as shown in figure 1. In this picture the in-feed and out-feed rotary accumulators and the center vial feed wheel can be observed. All materials are 316 stainless or other FDA approved materials for the clean-room environment. The operator places empty vials on the in-feed accumulator where they are automatically fed to the two fill positions, filled, and then moved to the out-feed accumulator. The operator removes the filled vials for packaging. The system can run continuously or in batches.

MONOBLOC 7000 Top Fill
FIGURE 1 (Click to Enlarge)

The difficult feeding and dusty powder is fed by standard FillPro feeders utilizing declination, special agitators, and ionization covers over the feed troughs. The feed components can be adjusted and removed for cleaning quickly without tools.

The hoppers/feeders of the 2 fill heads are shown in figure 3.

antibiotic fill heads
FIGURE 3 (Click to Enlarge)

The system could deliver 100 % good fills with the very difficult powder at a rate of 5-8 seconds over a range of 0.5-2 grams at 1% tolerance. All fills are net weight checked and cycle time includes reject of any out-of-tolerance fills. All fill data is recorded and presented in SPC format. This system, shown in figure 4, is a FillPro standard product built with accessories for this specific application using standards for GMP and clean-room environment.


FIGURE 4
(Click to Enlarge)

CASE 4:

THE CHALLENGES

  • Material in form of large pellets
  • Requirement to both preweigh and checkweigh
  • Explosive hazard materials
  • Very large fills with very precise tolerances with 100 % net-weight verification
  • High production rates

THE SOLUTION

A large jumbo frame with Model 7000 DX and jumbo material handling components are used in conjunction with FillPro's patented "piggyback" dual feeder for pelletized materials. This Patented feed system provides high feed rates for fast fills, coupled with a single pellet feeder for precise top off of the fill. The jumbo system is shown in figure 1. Please note the large pre-weigh pan, the large transfer funnel, the reject container, and the checkweigh scale.


FIGURE 1 (Click to Enlarge)

The system for the explosive hazard pelletized material could deliver 100 % good fills at a rate of 400 fill per hours with a target weight of 5000 grams plus or minus 5 grams (0.1%) tolerance. All fills are both pre-weighed and checkweighed per customer requirements and the cycle time includes reject of any out-of-tolerance fills. This system was built from FillPro standard products and accessories to the NFPA requirements for explosive hazards for Class 2, Div 1 environments.

The Patented Dual "Piggyback" feeder for large pellets is shown in figures 2 and 3.


FIGURE 2 (Click to Enlarge)


FIGURE 3 (Click to Enlarge)

The jumbo filler comes in several versions. Figure 4 illustrates a top load configuration that fills directly into the container. This configuration is shown with a Pneum-a-vac unit on top of the infeed hopper providing ease of material re-supply.


FIGURE 4 (Click to Enlarge)




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