Reliability has been
confirmed through
extensive testing and we
are now able to identify
and reject individual
canisters in a continuous
process situation.
around the MDI cannister is purged, with
the pucks then individually sealed. The
location of the individual MDI canister is
identified before the gas analyser removes
a sample from the puck to measure any
propellant gas leakage. Extremely low gas
leak rates have been proven to be reliably
detected. Speed and accuracy of integrated
communication is vital, where the result is
communicated by dedicated active digital
signal to an industrial PC running Mitsubishi
Electric’s MAPS SCADA software, which
analyses the data.
The status of the individual MDI test is
logged by the PLC. The MDIs are then
removed from the pucks by the robot to a
constant speed outfeed conveyor, with their
location tracked. Exacting synchronisation
by the robot is necessary to ensure
accurate placement of the MDIs, but in the
unlikely event, fallen canister detection also
features. MDIs with identified leakage are
removed at a reject station on the outfeed
conveyor and collected in a reject bin with
level detection. The volume of canisters
which ‘pass’ is monitored as well as the
number of rejects, with an alarm in the
event of an excessive reject quantity.
The carousel conveyor transports the pucks through a gas analyser system tunnel,
containing a gas leak detector. MDIs with identified leakage are removed at a reject
station on the outfeed conveyor and collected in a reject bin with level detection.
Taking MDI canisters from an upstream
external conveyor, it moves them onto an
infeed conveyor with upstream machine
monitoring and queue control ensuring
synchronisation. MDIs are then picked
and placed into individual pucks, six at a
time and transported on a constant speed
carousel conveyor, with queue control
maintaining back pressure to prevent
misfeeds. If required, fallen canister
detection will signal an alarm for operator
intervention.
Accuracy and repeatability are critical to
ensure speed and reliability of operation,
carried out by two, four-axis Mitsubishi
Electric’s RH6 SCARA pick and place
robots; one operating infeed of the puck
contained MDIs, the other the outfeed.
The robots are controlled by a high-end
Mitsubishi Electric’s Q Series PLC. Steve
Kirby, Key Account Manager at Mitsubishi
Electric, adds: “To meet the high levels of
accuracy required by the system, we put
together a highly integrated suite of highperformance
components.”
The carousel conveyor transports the
pucks through a gas analyser system
tunnel, containing a Cascade CT300 gas
leak detector, also controlled by the PLC.
Immediately before entering the tunnel, air
Full downstream machine monitoring
enables smooth flow of returning MDIs,
with optional downstream queue switch
to prevent build-back onto the production
conveyor. Controls for temporary buffer
storage via a rotary table are also available.
The resulting throughput is 180 canisters
per minute. Mitsubishi Electric’s MAPS also
produces an exportable report of canister
analytical data for each batch, stored in
an SQL database, accessed via the IPC’s
touchscreen display.
Extensive tests of Optimal’s system
have been carried out, combining high
detection rates with speed, accuracy and
repeatability. The machine is now available
as a standard proven design, meeting
pharmaceutical regulations FDA 21 CFR Part
210/211 - Pharmaceutical Industry GMPs, and
FDA 21 CFR Part 11 – Electronic Records and
Signatures.
For further information, please visit www.optimal-ltd.co.uk
Issue 45 PECM 61