Many factors must be considered in handling an automated packaging system ranging from meeting FDA requirements to speed and consistency.

Surviving in today’s highly competitive pharmaceutical industry requires manufacturers and contract packagers to streamline production processes and optimize manufacturing methods without sacrificing quality or contamination control. Reducing costs and waste, improving productivity, and maximizing capacity on production lines are just a few ways to accomplish this challenging goal.

I spoke with Ignacio Muñoz-Guerra, General Director, AutoPak Engineering Corporation, a manufacturer and integrator of stainless steel conveyors and ancillary packaging equipment, about how pharmaceutical manufacturers can get the most out of their existing lines and what they should consider when building a new line from scratch.

Q: Conveyors are obviously an important part of the production process since they move product from station to station. What kinds of problems are encountered?

A: Product disturbances typically cause the most problems for conveyors. Defined as a variation from the normal process, disturbances often cause machine failure due to disoriented products. Disturbances can result from inappropriately adjusted guide rails, the transfer of packages between two conveyors, or excessive vibration on pulsating thermoplastic belts. Well-designed conveyor systems should allow for repeatable positive positioning of guide rails through mechanical stops or position feedback. These features facilitate quick, accurate setup and allow operators to open or close a section of conveyor guide rails to suit the different-sized products. In addition to quick adjustment, these features should provide a digital readout, color-coding, or other methods that indicate specific guide rail positions for different sized containers. This information allows operators to establish pre-set standards, eliminating guesswork and saving time.