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Particle inspection equipment delivers savings, benefits

Custom particle inspection labeling machine with camera-based inspection set to be operational at a pharmaceutical company by late 2015.

Overall with remote inspection table for two operators.
Overall with remote inspection table for two operators.

Fiscally responsible companies make capital investments when they can justify the expense.

For one pharmaceutical company, that’s the case with its investment in a Particle Inspection and Labeling machine, designated as the PIL-30, which produces 30 inspected, filled, and sealed syringes/min. Per contractual agreements, the company’s name cannot be revealed, but the benefits from the PIL-30 will extend beyond financial ROI. They will include:

• Meeting U.S. FDA inspection requirements of USP <1> Injections’ 100% inspection requirement by satisfying USP <790> Visible Particulates in Injections inspection procedure. This system also meets the European Pharmacopeia EP 2.9.20 Particulate Contamination: Visible Particles inspection requirements.

• Eliminating the need for eight to 10 inspectors operating 20 hrs/day on the line, which is now accomplished on a single shift with two operators

• Replacing manual labeling and pouching functions with fully automatic equipment, providing labor savings

A representative for the pharmaceutical company says the cost savings of an automated system compared with the previous manual method breaks down as follows:

“Based on an average of 30 syringes a minute needing to be inspected, with an operator inspecting for 15 minutes then taking a five-minute break, 11 inspectors were required per shift to keep up with this volume.This minimum of 22 inspectors per day [two shifts] were additional headcount, plus the hiring and training, labor costs, gowning costs, annual inspector vision exams, increased bioburden loading of the cleanroom, lunchtime breaks, etc., made the evidence pretty compelling that an automated approach had to be taken.Also, this would amount to nearly doubling the production workforce for doing inspections only.”

It was noted that commercially available12 inspector manual systems cost in the neighborhood of $100K, plus they take up a considerably larger area of the room.

The PIL-30, also referred to as the SASI-30, is the result of a new venture called Particle Inspection Technologies. PIT is a partnership between Luciano Packaging Technologies, Inc. (LPT), developer of customized packaging machinery, and Wierciszewski Controls, which specializes in custom machine design, vision inspection integration, PLC and motion programming as well as custom HMI design.

Pharmaceutical focus

LPT President Larry Luciano says the company continues to manufacture and build products and services for food, consumer products, and other applications, yet focuses on the pharmaceutical and medical device sectors.

“We do custom work almost exclusively,” says Luciano. “And when you are developing customized machinery, as opposed to a standard piece of equipment, you have the opportunity to explore the latest developing technologies and use them in solving problems. Many of our customers are in ‘big pharma’ and medical device industries and have the wherewithal to be able to use and specify the latest technology.”

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LAST CHANCE TO SAVE! New Tech for Life Sciences at PACK EXPO Southeast