Dpp-260h High-Frequency Blister Packing Equipment for Capsules

Product Description

Application

The DDP-260H automatic aluminum-plastic blister packaging machine is an improved equipment recently launched by our company. It adopts variable frequency speed regulation and mechanical, electrical, optical and gas integrated control technology, and is innovatively designed in strict accordance with the standards of the pharmaceutical industry (GMP). It is at the leading level in China. It has advanced functions, simple operation and high output. It is the most ideal packaging equipment for large and medium-sized pharmaceutical companies, health products and food industries.

Performance characteristics

(1) The overall open layout structure and modular design provide good visibility of the workstations, convenient maintenance and adjustment, novel and safe appearance protection design, and safe operation. It adopts high-end PLC control, touch screen operation, Chinese and English digital display, variable frequency speed regulation, servo traction (with reducer), and the traction length can be adjusted arbitrarily on the touch screen within the traction size range, which greatly improves the stability of traction and saves test time and test consumables.
 

1. This machine uses the latest technology to improve the cam, and the guide plate rises and runs in a buffered manner, so that forming, heat sealing, creasing, and traction are effectively coordinated, so that the entire machine station can run smoothly at high speed. It has heating temperature control detection, host overload protection, PVC and PTP packaging material level detection, feeding and storage bin level detection control, automatic fault diagnosis alarm prompt, and automatic shutdown protection functions.
2. The modular horizontal design structure of the whole machine station has good visibility, making operation safer and more convenient. The equipment is equipped with a high-strength PC endurance board cover to prevent workers from being scalded or crushed during the startup process, greatly improving safety performance.
3. The stable frequency of aluminum-plastic plate punching of DDP-260H is 45-55 times/min.
4. The molding heating mechanism adopts contact-type plate heating, which can delay the start-up after the heating plate is lowered, limiting the material waste within one plate stroke; and reduces the heating power and heating temperature, saving energy and enhancing the stability of the plastic sheet, which is not easy to deform.
5. The enlarged PVC quick-change material receiving platform, quick material receiving platform, and whole machine guide rail increase the practicality of the whole equipment.
6. The mold is positioned in a trapezoidal shape, and the rectangular design is positively pressed, making replacement more convenient and quick. (You only need to unscrew the handle to replace the mold, and the punching station can be directly extracted and replaced from the front, achieving the fastest replacement speed. The old equipment requires special tools to loosen multiple nuts before extracting and replacing the punching, and the process is relatively complicated.) All parts that come into contact with the drug are carefully made of high-quality stainless steel and high-quality aluminum alloy non-toxic materials, with high-grade surface treatment technology, and the texture is prominent.
7. Air cushion seal: When the machine is stopped, the cylinder automatically raises the patterned plate. The deformation of the blister caused by heat radiation during the stay is eliminated, which is convenient for the cleaning of the patterned plate, and at the same time plays a buffering role of overpressure, which is beneficial to extend the service life of the machine.
8. The upper and lower patterned plates are heat-sealed in pairs: that is, both the front and back sides are dot-shaped patterns. Due to equal stress, the plate is flatter and the sealing performance is improved.
9. An independent batch numbering station is added, which eliminates the previous disadvantage of hot hands when changing the heat sealing mold, and a batch number heating mechanism is designed to ensure the clarity of the batch number.
10. The main components are imported, which improves the service life and grade of the equipment. The whole machine adopts a split connection design, which is easy to enter the elevator and workshop.

    Equipped function
    Basic functions	1. Automatic PVC feeding, material shortage alarm, automatic feeding, material receiving table 2. PVC preheating and molding; 3. Various automatic feeding devices (specially configured according to the packaging items provided by the customer); 4. Imaging detection device (optional according to customer requirements); 5. Heat sealing, cooling, shaping, traction, automatic plate alignment; 6. Automatic aluminum foil feeding, material shortage alarm; 7. Heating type batch numbering and indentation; 8. Punching, orderly output, automatic waste rejection, and orderly output of finished products.
    Basic Performance Features	1. The whole machine adopts a frame-type semi-enclosed transparent structure of endurance board shield to avoid harm to the human body during the operation of the machine. 2. The equipment adopts full servo drive to ensure the accuracy of each step and achieve absolute synchronization of each action; 3. It has heating plate temperature control detection, main motor overload protection, feeding storage bin material level detection control, fault automatic shutdown protection; 4. Moving component position monitoring overload protection photoelectric (anti-stuck), fault alarm and fault protection automatic shutdown system; 5. Online imaging visual inspection can be configured to ensure the quality of finished products (optional according to customer requirements) 6. Block positioning and directional output is conducive to connection with subsequent processes, such as pillow packaging machines, cartoning machines, etc.); 7. Material level detection and storage level status detection of packaging materials such as PVC, PTP packaging materials, capsules, etc., fault prompt alarm and automatic shutdown system; 8. PLC microcomputer control, touch screen operation, Chinese and digital display, fault diagnosis prompts, simple and convenient operation and maintenance.
    Structure and Manufacturing
    Materials	1. Except for special materials such as punching dies and forming dies, austenitic stainless steel or other materials with anti-rust coatings that are resistant to weak acids and weak alkalis are mainly used. Non-metallic materials are non-toxic, do not undergo chemical changes with drugs, and do not corrode or absorb drugs; 2. The surface of the machine cover is made of austenitic stainless steel brushed plate or matte treatment; 3. Parts with chemical plating and other surface treatments should be free of rust and peeling, and meet GMP certification requirements.
    Overall Structure and Manufacturing	1. The outer surface of the equipment is smooth, neat, beautiful, with transition chamfers and rounded corners, and the outer surface of the equipment is mechanically polished. The machine shell can be fully opened, easy to clean and maintain the interior, the surface of the working area is smooth, there are no dead corners and blind corners, easy to observe, easy to clean, and easy to install and disassemble the mold; 2. The surfaces of the channels and related parts that are in direct contact with the filling are polished and easy to clean, without dead corners, sand holes and slits; 3. The machine mechanism has an adjustment device to adapt to changes in specifications and materials; 4. The mold replacement is equipped with a positioning device, which is convenient for installation, disassembly and cleaning, and meets the requirements of GMP certification.
    Substrate heating and molding device	1. The replacement and installation of the composite aluminum foil coil is simple and convenient. The substrate conveying process has a clamping device and the guide surface is smooth. The entire conveying, guiding and clamping process does not damage the substrate surface; 2. The heating adopts intermittent heating molding, and the heating temperature is slightly higher than the molding temperature. 3. Compressed air positive pressure molding is adopted. In addition to the molding high-pressure air, the molding table is equipped with a balanced high-pressure air, and the compressed air introduced into the balance chamber is adjustable to ensure the fullness of the blister molding; 4. On the molding table, the reciprocating motion of the molding upper mold uses a cam rocker to drive the up and down reciprocating motion to complete the mold closing and blowing bubble cover molding.
    Traction servo device	1. The servo drive stroke relies on the clamping force to move the base material and the cover material synchronously, achieving synchronization with the stitching station, making the stepping accuracy more precise; 2. The servo drive stroke is adjustable, using a knurled wheel and a rubber roller to clamp the feeding mechanism. The traction stroke can be changed at will on the touch screen to adapt to changes in the plate specifications. The adjustable stroke is generally 40-130 mm.
    Feeding device equipped	1. Ordinary feeder 2. Disc vibrating feeder 3. Liquid feeder 4. Plate feeder 5. Injection feeder              Optional according to customer requirements
    Feeding heat sealing device	1. The replacement and installation of the composite aluminum foil ring material is simple and convenient. A clamping device is provided during the conveying process of the substrate, and the guide surface is smooth. The entire conveying, guiding and clamping process does not damage the surface of the substrate; 2. The heat seal adopts a flat heat seal, and the upper and lower heat seal plates move up and down intermittently. The upper heat seal plate is fixed and equipped with an electric heater. The upper heat seal plate should be made with a convex grid pattern or convex points. 3. The lower heat seal plate uses a cam or a gas-liquid booster device for intermittent reciprocating movement up and down.
    Typing breaking line and punching device	1. The typing device, the breaking line and the punching device adopt a four-column guide column structure. The typing and breaking line are synchronized with the entire traction and intermittently move, and a cam reciprocating motion structure is adopted; 2. The typing adopts cold pressing of steel stamps, and the steel characters of the pad pressing printing batch number are quick and convenient to install and disassemble. The printed batch number is clear and legible, without overlap and blur, the printing position deviation is ≤1.5mm, and it can adapt to multi-row batch number printing; 3. The breaking line adopts cold pressing or hot pressing device, generally cold pressing, the stamping knife is serrated, and can cut through the substrate to form a dotted line; 4. The punching device is punched into blocks through the concave and convex die, and consists of block collection and waste collection. The punching structure adopts four-column guide columns and needs high-precision linear bearings to ensure the reciprocating motion accuracy of the concave and convex die; 5. The stamping knife and concave and convex die are made of tool steel and heat treated to ensure their hardness and service life; 6. After punching, straight-edge waste can be collected in a circle and punched out.
    Cooling system	1. Electric heating parts such as heating and heat sealing need to pass through cold water pipelines to ensure the safe use of electric heating elements and bearings; 2. The cold water pipeline is well sealed and easy to install, disassemble and clean. The pipeline system has adjustable and display functions for water pressure, and the water level can be displayed.
    Compressed air	1. The air source needs to pass through the terminal filtration and oil and water removal three-in-one filtration device, with adjustable water pressure and display function; 2. The air path to the formed air cavity is convenient for assembly, disassembly and cleaning, and the air cavity is evenly distributed.
    Transmission mechanism	1. The main machine is driven by a three-phase asynchronous motor 2. The traction is driven by an independent servo, which is high in precision, stable and reliable in operation; 3. The whole machine has stable transmission and low noise.
    Lubrication system	All parts that are in direct contact with the base material, cover material and filling material use oil-free bearings, which do not require lubrication and do not pollute the blister packaging.
    Electronic and Control
    Speed adjustment	1. The machine speed can be programmed and displayed, and the speed can be set and controlled manually; 2. The filling drug delivery oscillation frequency is adjustable.
    Control functions	1. It has button control and analog screen display control, including inching, starting, linkage, variable frequency speed regulation and other function switches and displays. 2. It has current and voltage display and overcurrent and overvoltage protection devices, and the status has heating and sealing temperature display and setting, and the temperature display sensing accuracy is ±2ºC. 3. It has the function of setting production data and displaying output, speed and time, and can perform real-time output and cumulative output statistics; 4. It has PLC display and control, and touch LCD panel. The interface design is divided into manual operation interface and normal operation operation interface. According to the selection of process menu and parameter setting, it can display set parameters, actual working parameters, statistical data and fault causes. The system itself has a strong self-diagnosis function, which can reflect faults and troubleshooting methods online, and can calculate the output of the equipment during operation by touching the output monitoring button, and can perform regular statistical printing and LAN connection control.
    Chain Requirements	It is equipped with a delayed start function to avoid any waste of time when shutting down or starting up.
    Monitoring safety requirements	1. Main motor fault protection; 2. Automatically shut down and alarm when the following situations occur: a. When the cooling water system is short of water or under-pressure; b. When the compressed air pipeline fails or is under-pressure; c. When the electric heating system is over-current and over-pressure; d. When the temperature of the electric heating system is greater than the set value ±5ºC; e. When the base material and cover material ring tend to be empty; 3. The electrical control should have a self-protection function to prevent damage to the equipment due to misoperation.
    Connectivity	A control interface is provided to receive the shutdown and deceleration instructions required for the next process.

    
    
    
     

    Environmental and indicator requirements
    Installation Environment	The whole machine is in a 300,000 class clean space, including plastic feeding, heating, molding, stepping, filling, loading, heat sealing, typing, indentation fracture line, punching and other processes.

     

    Verification Standards
    Material	Provide the machine with GMP compliance validation plan (draft), operation SOP, maintenance procedures and cleaning and sanitation procedures.
    Verify key control indicators	1. Blister packaging punching speed, meet the production requirements; 2. Blister packaging appearance: a. The aluminum foil and the base material are not allowed to separate at the corners; the blister is complete, smooth and crisp; b. The aluminum foil and the base material are tightly combined, flat, with clear mesh and no wrinkles; 3. The sealing performance of the finished blister packaging product, the finished product sample is placed in a sealed container, vacuumed, and the vacuum is maintained at 80KPa for 30sec, and a water ingress test is performed to observe whether the finished product sample has water ingress; 4. Measuring verification of counting.

Transmission structure (refer to the transmission principle diagram in the attached figure)

This machine uses a 3kw motor as the main power through a planetary gear reducer and a mechanical transmission chain to achieve synchronous operation of all the moving parts of the whole machine - sheet heating, blister forming, heat sealing, batch number printing, tear line pressing, and plate punching as required.

Blister Forming

Turn on the machine and press the upper heating and lower heating function control keys in manual mode on the screen. The upper and lower heating plates are closed, and the PVC plastic sheet is preheated between the upper and lower heating plates. After preheating, it enters the blister forming mold under the action of traction. The lower mold of the forming mold is fixed, and the upper mold of the forming mold rises to the upper limit under the action of the cam and presses the PVC plastic sheet. At this time, the air valve opens, and the compressed air that passes through the filter pressure reducing valve enters the forming mold through the upper mold. The lower mold cavity, the PVC plastic sheet is positively pressed into shape.

 

Material Filling (Configure the feeding system according to user requirements)

The medicines are sent from the material receiving bin to the material control station, pill scattering station, pill distribution station through the material discharge switch, and then to the heat sealing station. The medicines are sent out from the material control port and the pills are quickly dispersed by the pill scattering brush, and then pulled into the pill distribution station, where the two-stage pill distribution and brush roller evenly distribute the dispersed pills on the formed blisters.

Filling detection (Special order model)

The camera detects the feeding situation and detects the filled blisters entering the detection area. The detection results are input into the system and memorized, and the automatic separation of finished products and waste products (i.e. waste rejection function) is realized under program control.

 

Heat seal

The filled PVC plastic blister and aluminum foil enter the heat sealing mold and are sealed by flat pressure to complete the heat sealing.

Batch number

The heat-sealed medicine plate enters the batch number mold, which moves up and down, and the batch number is printed at the corresponding position.

Indentation

The medicine plate enters the indentation die and falls into the indentation cavity. The indentation die is equipped with an indentation knife. The indentation die moves up and down to leave indentation lines or tear lines at the corresponding positions of the medicine plate. The indentation die is a special ordered die (the indentation die can be omitted for the plates that do not need to be pressed).

Blanking

The traction mechanism sends the heat-sealed, batch-numbered and indented medicine plates into the punching die. Under the action of traction, the medicine plates pass through the punching die. At the same time, the punching die punches and cuts the medicine plates according to the mold print, and the waste coils are automatically rolled up. The medicine plates are automatically transported, and the finished products are separated from the waste products, and the finished products are output.

Main technical parameters of DDP-260H aluminum-plastic blister packaging machine

Number	Program		Technical indicators
1	Punching frequency (standard version)		20-60 times/min (aluminum foil) 15-30 times/min (aluminum aluminum)
2	Maximum forming area and depth		250×110×22 (aluminum-plastic) 250×110×18 (aluminum-aluminum) Large honey pill 250×110×26 (aluminum-plastic)
3	Travel range		30-120 (30-140mm can be customized)
4	Plate Specifications	Standard	57×80mm
		Reference specifications	88×57 95×65 100×43mm (can be designed according to user requirements)
5	Packaging materials (Rolls are all Φ75)	Non-toxic PVC hard sheet	(0.15~0.4)×260×(Φ600)mm
		Heat seal aluminum foil	(0.02~0.15)×260×(Φ300)mm
		Formed aluminum foil	(0.16~0.2)×260×(Φ600)mm
		Heat seal dialysis paper	(50~100)g/×260×(Φ300)mm
6	Heating power	Upper heating plate	2kw
		Lower heating plate	2kw
		Heat sealing heating	2kw
		Batch heating	0.175kw×3
7	Main motor power		3kw
8	Power supply, total power		380V  50Hz  10kw
9	Clean compressed air		0.6~0.8Mpa
10	Air consumption (air compressor)		≥0.25~0.5m³/min
11	Mold cooling		Tap water or circulating water consumption: 60-100L/h
12	Overall dimensions (length x width x height)		4775×760×1620 (middle split, including foot height)
13	Machine weight		About 2088kg

DDP-260H aluminum-plastic blister packaging machine main electrical components configuration list

Number	Name	Models and specifications	Manufacturer or factory	Quantity
1	Breaker	NXB-63/3P25A	CHINT	1
2	Breaker	NXB-63/1P10A	CHINT	2
3	Breaker	NXB-63/1P16A	CHINT	1
4	Breaker	NXB-63/2P16A	CHINT	1
5	Contactor	NXC-25	CHINT	1
6	Contactor	NXC-09	CHINT	1
7	Servo Motor	MSMF042L1U2M	Panasonic Japan	1 pair
8	Servo Drives	MBDLN25SE
9	Servo reducer	VR78L2-15-P2-S2/	China	1
		14-30-50-70-M4
10	Programmable controller	CP1H-X40DT-D	Germany	1
11	Temperature Module	SMC60S-0040	China	1
12	Output Module	CP1W-8ET	Germany	2
13	Encoder	EDG3801S4B500F9-26R2	China	1
14	Switching Power Supply	S8JC-C10024	China	1
15	Frequency Converter	MD200T3.7	China	1
16	Touchscreen	FE6070H	China	1
17	Intermediate relay	NXJ/2ZD	CHINT	9
18	Solid State Relays	SSR40	China	4
19	Proximity switches	E3-D4NK	China	2
20	Proximity switches	TVPE:J2-D4NK-M	China	4
21	Magnetic switch	H12-D5NK	China	1
22	Main motor	100L-4 (3KW)	China	1
23	Reducer	WPA-100-10A	China	1
24	Warning light	XVGB3SMA 24V ac/dc 180mA	China	1
25	Feeding motor	Z5D120-220GU-5GU40KB(120W220V)	China	1
26	Block output motor	3IK15RGN-C-3GN150K(15W220V)	China	1

DDP-260H aluminum-plastic blister packaging machine

DDP-260H aluminum-plastic blister packaging machine layout

Detection effect diagram