Solutions for Effervescent Products

The new business model from Romaco sets valuable incentives for meeting customer requirements. For the design of innovative solutions, Romaco relies on its unique knowledge portfolio. With its diverse brands, Romaco focuses on important technologicalfields of competence. The single product lines offer the optimum

prerequisite for the development of comprehensive solutions.Romaco promises its customers professional project handling, fast delivery times and a reliable service. Through this, Romaco provides its customers with a considerable boost to their earning and financial power.

Creating Value –best price/performance ratio

Romaco wins over its customers by offeringan outstanding price/performance ratio overthe entire life cycle of its products. In thisway, customers can systematically optimisetheir cash flow. With efficient productionand service management, Romaco preparesits customers for future long-term commer-cial success.

Delivering Solutions –high application expertise

Romaco offers integrated solutions forthe growing markets of pharmaceuticals,cosmetics, food and industrial applications.Here, the customer benefits from the syn- ergetic effects that result from the closecollaboration of all the Romaco brands. This internal technology transfer imparts a considerable development potential and is the basis for comprehensive solutions.

Exploiting Technologies –strong brands

Romaco is synonymous with European engineering on the highest level. With its seven brands, the company is widely recognised around the world. Continuity and progress are the keys to a strong posi- tioning on the market. Romaco relies on the profound knowledge and the long-time experience of its employees.

Beyond Technology

Delivering Solutions High-tech Concepts for Effervescent Products

Romaco is the foremost supplier in the effervescent tablets sector. Our all-in-one solutions integrate four process steps: tab-leting as well as primary, secondary and final packaging. Various transfer systems round off the portfolio. The fragile efferves-cent products can be packed in heat-sealed strips or rigid tubes. Each effervescent line is individually configured according to the application – the sole criterion is what our customers want.

»For many years now, we’ve trusted in solutions by Romaco Siebler, the industry’s technology leader, to pack our effervescent tablets in strips and rigid tubes.«

Helmut Jakolat, Production Technology Manager, HERMES ARZNEIMITTEL GmbH, Germany

Production of Effervescent Tablets

• Freely scalable solutions for tableting effervescent products

• Safe processing of hygroscopic powders• Tablets with a smooth, polished surface• Reduction of lubricants provides optimal

hardness• Tablets dissolved without a grease film

Packaging in Rigid Tubes

• Ideal for filling into plastic or aluminium tubes

• Tubes in a variety of shapes and sizes• Reliable processing even of very short

tubes ≥ 50 mm• Many different closures, stoppers and

caps can be applied• Inkjet printing

Packaging in Sealed Strips

• Unit dose packaging of effervescent tablets

• Air, light and moisture-tight strip packaging

• Soft compound aluminium foil material• Aluminium foil thickness reduced to

≤ 10 µm• Strip formats and geometries can be

varied• Print mark registration possible for both

foil rolls

Secondary Packaging

• Folding cartons as secondary packaging• Intermittent or continuous motion

cartoners• Insertion of leaflets or medical devices• Glued or tuck-in closure• Tamper-evident features

Final Packaging

• Stretch or shrink wrapping• Shipping cases as final packaging• Adhesive tape or hot melt closure

Effervescence Concept for Rigid Tubes

Kilian tableting solutions are used to com-press the effervescent formulation as the first stage in the process chain. The tablets are then fed directly from the scraper of the press to the feed unit of the Siebler rigid tube filling machine by means of a special transfer system. There they are filled safely into the tube and the lid is closed – the fragile effervescent tablets are now ready to be packed in folding cartons. Finally, the secondary packaging units can be bundled

Delivering Solutions

and/or packed in shipping cases. Suitable cartoning and final packaging solutions are supplied by Promatic for this purpose.The effervescent tablets can be manufac- tured and packed in a very small space in this way. Non-linear arrangements of the individual components are also possible because our transfer solutions are flexible. A perfect solution exists no matter how little room is available – that’s the Romaco maxim.

Tableting Effervescent Products

• Application-specific solutions for com-pressing effervescent tablets

• External lubrication with magnesium stearate

• Integral transfer from the press to the rigid tube filler

• Broken tablets and product waste re-duced to a minimum

Filling the Rigid Tubes

• Filling volume on the tablet infeed con-veyor can be adjusted independently of specific formats

• Lateral stoppers permit stress-free separation of the filling volume

• Filling possible in two steps: the filling volume can be varied within a wide range

• Gentle filling of fragile tablets according to the rotation principle

• Controlled erection of the effervescent tablets by varying the rotation speed of the filling cartridges

Versatile System

• Suitable for a wide variety of products and packaging

• Even very short tubes can be processed• Equipped with only a small number of

compact format parts in the basic version• Quick and easy retooling• Tablet conveyor belt can be exchanged

without tools in a matter of minutes• Easy access and cleaning• Bespoke transfer solutions allow optimal

use of space

Optimal Process Control

• Several servo drives can be integrated• Efficient elimination of dust and breakage• Automatic tube level indication• Pick & place systems enable safe

handling of the rigid tubes• Customer-specific marking solutions• Controlled transfer to downstream line

components

Effervescence Concept for Strips

Romaco unites the expertise of Kilian, Siebler and Promatic to provide integrated strip packaging lines. As a single-source supplier, we develop end-to-end concepts for effervescent tablets including manufac- turing and packaging. Our portfolio covers tableting and primary packaging in sealed strips. A broad array of cartoners and final

Delivering Solutions

packaging solutions is also available. Contin- uous production processes can be realised because the heat-sealing machine has a direct connection to both the tablet press and the cartoner.

Tableting Included

• Specially designed tablet presses for manufacturing fragile effervescent tablets

• Innovative compression technology enables superior product quality

• Integral transfer to the heat-sealing machine

• Broken tablets and waste reduced to a minimum

Bespoke Transfer Systems

• Customer-specific configuration of the interfaces between the different line components

• Safe product transfer from the tablet press to the heat-sealing machine

• Strip packs can be transferred into the cartoner with FixTrans or FlexTrans

• FlexTrans for frequent changeovers• FixTrans for very big batches• Reliable transfer solutions for a broad

range of applications

High Level of Automation

• Servo motors guarantee maximum precision and efficiency

• Up to six FlexPickers enable the system to deliver as many as 900 strips per minute

• Central communication control at the interfaces

• Numerous camera systems monitor the entire production process from end to end

Flexible FlexTrans

• FlexTrans facilitates flexible-format transfer solutions

• FlexPicker robots work virtually independently of specific formats

• Strip layouts and stack heights can be easily adapted

• Strip packaging lines can now be retooled quickly for the first time

• Excellent OEE values thanks to high availability, strip pack quality and output

Exploiting TechnologiesRomaco Kilian KTP X Series

Tableting Effervescent Products

Cool – fast – clean: these three design features of the Romaco Kilian KTP series make both a qualitative and a quantitative difference, especially when the aim is to compress effervescent tablets. Cool pro- duction temperatures, shorter retooling and cleaning times and an optimised hygienic design ensure an absolutely reliable process. Cool – Optimal Cooling• Process temperature less than 30 °C• Smooth-running compression rollers

restrict frictional heat to a minimum• Efficient cooling of the torque drive

and V-ring seals• Cooling ring underneath the die-table

acts as a thermal barrier• Magnetic brakes bring down the pro-

cess temperature• Fill shoe with external gear reduces

heat input

Fast – Ready in Minutes• Optimised retooling and cleaning times• Die-table, tablet chute and fill shoe can

be swung right out• Number of product-contacted parts sys-

tematically reduced• Toolless format changes

Clean – Hygienic Design• Strict separation between the com-

paction, retooling and service areas: no tablet dust enters the machine com-partment

• Patented punch bellows protect the tab-lets from lubricants and avoid black spots

• Washable fill shoe and tablet chute• Dustproof tablet chute

Clear Advantages

The Kilian KTP 590X single-sided rotary press for mono and bi-layer tablets is equipped with three compression rollers and is hence ideal for tableting effervescent products.

• Tableting in three steps: tamping, pre-compression, main compression

• Extended dwell time due to 28/41 tooling increases time for deaeration and reduces risk of capping

• Special fill shoe and paddle design• Uniform powder distribution in the die• Homogeneous compression• Optional stearate spraying system

reduces the ejection force• Optimised tablet chute ensures con-

trolled discharge

Clean: hygienic designFast: few product contact partsCool: at full speed

Exploiting TechnologiesRomaco TabTrans

Transfer System for Effervescent Products

Romaco TabTrans is a special transfer technology from Kilian and Siebler for effervescent tablets. This interface station assures fast and controlled transfer of the fragile tablets from the tablet press to the primary packaging machine. The system enables full use to be made of the capacity not only of the tablet press itself but also of the packaging machines installed down- stream. In short, it is a powerful and reliable interface solution that guarantees a contin- uous production process.

Innovative Transfer Belt

The compressed tablets are fed from the scraper directly to the Romaco Kilian conveyor belt. Thanks to the high conveyor speed, tailbacks of tablets at the press discharge are effectively prevented. The products can thus be removed gently and transferred safely.

• High conveyor speed helps separate the tablets

• Dedusting included• Integral process control (IPC) with

selective sampling• Built-in metal check unit for detecting

foreign particles

Proven Rotary Tables

Romaco Siebler’s rotary tables receive the tablets from the metal check unit and distribute them on the conveyor belt to the primary packaging machine. The newest generation of this series features a trans-parent protective enclosure which can be opened right up.

• Tablets distributed to the downstream packaging units

• Product flow slowed down and widened• Changes of direction possible• Transparent acrylic glass panels provide

an optimal view of the production process• Ergonomic design with a protective

enclosure which opens right up• Very easy to clean thanks to access

without tools

Sampling Products on the rotary tableHigh speed transfer

Exploiting TechnologiesRomaco Siebler STF 120

Effervescent Tablets in Rigid Tubes

The Siebler STF 120 rigid tube filling ma- chines pack effervescent tablets in plastic or aluminium tubes. Their ergonomic design simplifies operation, retooling and cleaning. The technology also impresses with a high output and an advanced level of automation. Reproducible parameters are the key to reli- able processes.

Gentle Tablet Handling• Effervescent tablets filled according to

the rotation principle• Safe processing of all tablets with a

hardness down to 40 N• Ideal for very small, thin and soft products• Rotating filling cartridges used to erect

the effervescent tablets• Adjustable erection and filling speed

Quality Makes the Difference• Absolutely easy to clean• Modular design and very small footprint• Equipped with only a small number of

compact format parts• Optional integration of instruments for

monitoring the process• Efficient elimination of dust and breakage

Versatile Machine• Suitable for handling any tube length of

50 mm or more• Filling volume can be adjusted indepen-

dently of specific formats• Format-independent adjustment possible

to different tube lengths

Tube Transfer System with Pick & Place• Pick & place module lifts the rigid

tubes to the filling station• Controlled tube discharge with

pick & place removal• Top performance because the tubes are

transferred to the filling station in clusters

Unique Feeding Concept• Reproducible adjustment of the tablet

thickness• Tablet conveyor belt can be exchanged

without tools in a matter of minutes• No need to secure the product feed

rails to the conveyor• Lateral stoppers permit stress-free

separation of the filling volume

Tablet filling according to the rotation principle

Tube transfer with pick & placeProduct feeding concept

Effervescent Tablets in Strips

The heat-sealing machines in the Romaco Siebler HM 1E series meet even the strictest requirements for packaging effervescent tablets in four-side sealed foil strips. This type of unit dose packaging is extremely air, light and moisture-tight and is particularly recommended for products which are highly susceptible to environmental factors. Thanks to the proven Siebler cutting and perforation technology, sealed strips with a variety of geometries and layouts can be realised. High speed production and premium sealing quality are the hallmarks of every Romaco Siebler solution.

Exploiting TechnologiesRomaco Siebler HM 1E Series

Extreme Precision• Bespoke sealing patterns• Reproducible sealing parameters• Sealing station can be quickly exchanged• Precise temperature distribution on the

sealing surfaces• Multiple heaters and temperature sensors

per sealing tool• Efficient control of temperature tolerances

Proven Design• cGMP compliant balcony architecture• Extremely compact design with a small

footprint• Ergonomic working• High feed rate

Safe Handling• Linear vibrator efficiently eliminates

breakage before the feed conveyor• Accumulating belt permits a continuous,

stress-free product flow to the feed station

• Bow feeder prevents broken tablets from becoming jammed in the feeding channels

Reliable Feeding• Controlled dropping of the tablets into the

sealing station from a very small height• Servo-driven rotary separation unit en-

sures precise product positioning• Horizontal product feeding also possible

Feeding Perforation Coding

Stacking with FixTrans

Romaco Siebler develops transfer solutions for strips with an identical width under the FixTrans label. The individually configurable unit stacks the sealed strips and passes them to the cartoner. FixTrans is particularly suited for large batches and blockbuster products. It can be adapted to different strip lengths and stack heights at any time. It is an impressive system offering high transfer speeds and reliable, cost-efficient operation.

User friendly• Selective sampling possible• Liftable overhead conveyor provides

optimal access

Robotic Transfer with FlexTrans

The robotic transfer units in the Romaco Siebler FlexTrans series enable the strips to be conveyed directly to the cartoner irre- spective of the format. Up to six FlexPickers transfer and stack the strip packs at very high speed. The servo-driven grippers work almost independently of specific formats. Product and packaging changes can thus be completed quickly and easily. The FlexTrans systems offer maximum flexibility whenever different pack sizes, strip layouts and stack heights are involved.

Format Flexibility• Robotic transfer for short set-up times

on the line• Format flexible stacking

Exploiting TechnologiesRomaco Siebler transfer solutionsFixTrans and FlexTrans

Interface Management• FlexTrans aligns the processes of up-

stream and downstream systems• FlexPickers control the transfer, ejection

and temporary storage of the strips• Integral buffers regulate the process• No overflow of good packs – all quality

approved strips are processed

Intelligent FlexPickers• Vacuum grippers achieve up to 200 picks

a minute• Pick & place system enables format

flexibility• Selective ejection of single strips possible

Direct transfer with FlexTransSampling with FixTransStacking with FixTrans

Continuous Motion Cartoners

The continuous motion cartoners in the Romaco Promatic PC 4000 series are ideally suited for a wide range of applica-tions. They are designed for both high speed operation and medium packaging speeds. These cartoning machines can be switched flexibly from continuous to inter-mittent motion – for processing high stacks, for instance. The PC 4000 cartoner series packs up to 420 folding cartons a minute in continuous mode.

Intermittent Motion Cartoners

With a maximum output of 150 folding cartons a minute, the Promatic PCI 915 intermittent motion cartoner represents the high performance class. The models in the Romaco Promatic P 91 series are available in a standard speed (P 91) or large packa-ging (P 91L) version.

Exploiting TechnologiesRomaco Promatic PC 4000 SeriesRomaco Promatic P 91 SeriesRomaco Promatic PCI 900 Series

cGMP Compliant Design• Balcony architecture conforms to the

highest pharmaceutical standards• Optimal view of the process• Cross-contamination is successfully

avoided• Very efficient line clearances

Ergonomic Design• Easy access reduces retooling and

cleaning times to a minimum• Retractable carton magazine allows op-

timal access to all machine components and simplifies format changes

• Ergonomic working height for maximum operating convenience

• Low vibration and noise levels thanks to servo motors and belt drives

Technical Highlights• Bespoke feed systems can be designed

on request• Positive carton opening system:

servo-controlled carton pick-up protects the materials

• Reproducible, toolless format changes in under fifteen minutes

• Torque limiters for all drives• Minimal costs for maintenance: toothed

belts and pulleys instead of chains and mechanical gears

cGMP compliant balcony designRobot feeding system for single or multiple strips

Carton positive opening and product feed- ing into cartons

Final Packaging Solutions

Romaco Promatic offers a wide range of final packaging solutions which can be flexibly configured according to the application.

Carton Bundling with the SM 2000

The stretch banders in the Romaco Promatic SM 2000 series can be supplied with a pneumatic (PV) or a servo (EV) drive. They are also available with an optional shrink tunnel. Depending on the model, these balcony design banders achieve a maximum output of 50 bundles a minute. The folding cartons can be bundled either lying down or standing up on edge. A complete format set consists of only three parts.

Semi-automatic Case Packer PAK 100

The Romaco Promatic PAK 100 is a semi- automatic case packer that is altogether affordable. This compact machine can be used to group, stack and pack folding cartons. The only manual steps are case erection, feeding and removal. Therefore PAK 100 is not only extremely reliable but also very simple to operate.

Fully Automatic Final Packaging Solution PAK 320

The Romaco Promatic PAK 320 case packer is a fully automatic final packaging solution. This side-loading machine fills up to eight shipping cases a minute at maximum speed. Either hot melt or adhesive tape closure is possible.

Exploiting TechnologiesRomaco Promatic SM 2000Romaco Promatic PAK 100Romaco Promatic PAK 320

Unique Features of the PAK 320

Ergonomic Design• Servo-controlled case handling with

positive opening system• Vibration-free and silent operation• Format changes in under twenty minutes

Quality Control• cGMP compliant balcony architecture• Easy integration of quality control

systems• Track & trace: customised solutions

for seamless tracking• Folding cartons identified layer by layer

PAK 320: carton flap closurePAK 320: automatic case erectionSM 2000: stacking unit and hot sealing bar

Creating ValueCreating Value – Romaco generatesadded value for the customer acrossthe entire life cycle of its solutions

• Romaco is interested in a long-term solution partnership with its customers

• Romaco is familiar with its customers’ critical success factors throughout the different life cycle phases of our jointly developed solutions

• The range of services from Romaco is specifically designed for these phases and is delivered through the appropriate modular components

• Romaco optimises the internal process- es so that the customer can benefit from more secure decisions within the time gained

• In April 2014 the new business unit Romaco Systems was founded within the Romaco Group: the aim of this unit is to integrate the offering of the Romaco Group into comprehensive solutions

We understand the business modelof our customers and with a diverseportfolio we offer the best price/perfor-mance ratio for generating additionalcash flow.

Benefit for the customer

Across the entire life cycle• Minimal life cycle costs and low TCO guar-

antee fast amortisation of the financial investment

• The wide range of customer service prod- ucts ensures sustainable value creation

In the investment phase (designing value)• Professional consulting to increase

decision-making security• Short processing and delivery times give

maximum scope for investment decision and thus optimum decision flexibility

• Customised solutions development for the optimum preparation of the imple- mentation phases (ramp-up and production)

• Reliable and customer-orientated project management according to efficient milestone principles provides professional delivery

In the ramp-up phase (leveraging value)• The production phase is reached more

quickly due to shortening of ramp-up• Transfer of expertise provides increased

security to the customer in implementing production systems at the highest level

• Minimisation of ramp-up costs

In the production phase(harvesting value)• Maintenance of the value stream due to

quick customer service response times• Best delivery times in service, format and

spare parts• Consulting on the optimisation of the OEE• Continuous training of the customer team• Extension of the life span

Creating Value describes our constantwillingness to secure our customers’ –and our own – financial success.

Customer Service

Competent partner throughout the operating lifespan

Spare Parts

• Spare parts packages tailored to each individual machine

• All spare parts available for a minimum of ten years

• Durable original parts that fit exactly• Short response and delivery times• Decentralised warehousing ensures

local availability

Original Parts

• Format sets compatible with all machines in the same series

• High-precision parts that fit exactly• Format centre: each part is rigorously

tested by Romaco before it leaves the factory

• Machine parameters and qualification documentation included in the scope of supply

Installation & Commissioning

• Installation: project planning and execution

• Commissioning and initial briefing for operators

• Qualification support• Ramp-up support with shortened

start-up phase

Training

• Qualified training and seminars for machine operators and maintenance personnel

• FDA compliant training concepts with continuous performance reviews

• Training provided on the customer’s site or at Romaco’s

• OEE support: systematic optimisation of overall equipment effectiveness

Retrofits and Upgrades

• General overhaul and modernisation projects help improve economic efficiency

• Individual solutions• Active obsolescence management

extends the service life• Feature enhancements enable increased

flexibility• Plant relocation planning and execution

Maintenance and Remote Assist

• Individual maintenance and Remote Assist contracts

• Remote Assist permits prompt and reliable diagnostics

• Real-time support thanks to customer service “at the push of a button”

• Virtual communication using smart glasses• Telephone hotline in case of an emer-

gency• Team of service technicians on hand to

carry out assignments worldwide

2017

/ 05

Romaco Pharmatechnik GmbHAm Heegwald 1176227 KarlsruheGermany

P +49 (0)721 48 04 0F +49 (0)721 48 04 211E siebler@romaco.com

www.romaco.com