What are the problems in the application of cartoning machine in pharmaceutical industry

The contradiction between the cost of drug packaging materials and the requirements of cartons for cartons In recent years, with the price reduction of drugs and the fierce competition in the drug market, pharmaceutical manufacturers pay more attention to the production cost In the process of reducing the cost of finished drugs, people pay more attention to the cost of cartons as medium packaging Even if a cartons can save 0.5 points, it is also a considerable cost for mass production If manual cartoning operation is adopted, the quality requirements of cartons are low, and their dimensions are compact, which will save at least 0.01-0.02 yuan for a carton However, once the cartoning machine is used, it will put forward higher requirements for cartons and instructions, and the size of cartons is larger than that of manual cartons The paper boxes and instructions required for production with cartoning machine are in 4.2.2.1 of the standard of multifunctional cartoning machine (JB / t10640-2006), and the paper requirements for cartons and instructions used for cartoning machine shall comply with table 2: the paper box size requirements for production with cartoning machine Generally speaking, the paper box size is considered in terms of cost saving, that is, the smaller the size, the more compact the better In the process of manual packaging, people's dexterous hands can put almost any product into the box, and the size of the box is small However, when using the cartoning machine, the tolerance between cartons and products should be considered In order to make the inner package into the box smoothly, the inner dimension of the box and the inner package should have a large interference fit, especially multiple inner packages (blister plate with instructions, oral liquid with pipette, etc.) should be put into the box at the same time The manual is usually "pushed" into the carton together with the inner package, so the two ends of the carton may not be the same length, so a large margin should be considered in the length of the carton For the same reason, the thickness of the manual takes up space, and the height of the carton should also leave space For general experience, please refer to table 3 for dimensions to design the carton The contradiction between the reduction of carton cost and the reduction of production cost after using the cartoning machine to solve the contradiction between the reduction of carton cost and the reduction of production cost after using the cartoning machine depends on the coordination and consideration of both the manufacturer and the user First of all, the users of pharmaceutical factories often only see the increase of cost of each carton in front of them, and do not comprehensively consider the cost reduction caused by the reduction of labor force after the use of the cartoning machine; secondly, the manufacturing accuracy of the equipment or some technical difficulties have not been fundamentally solved during the production of the cartoning machine, so that there are special requirements for the quality and size of the cartons, which also needs to be improved by the manufacturers, Even a 10 g / m2 reduction in carton quality makes sense The actual productivity and qualified rate of the box loader hinder the application of the domestic machine This paper analyzes the products of an old box loading machine factory in Shanghai Its model is a mapping imitation of NORDON company in Sweden The nominal speed of the product is 120 boxes / minute (max), but the normal starting rate can only be 80 boxes / minute Then, it analyzes the box loading machine with the speed of 180 boxes / minute (max) in a company in Shanghai, and the actual operation capacity is only 130 boxes / min The data survey listed indirectly reflects the poor production stability, which is due to the quality of both the machine itself and the mechanical carton The qualification rate of medical cartoning machine is in accordance with 6.4 of standard (JB / t10640-2006) The qualification rate of cartoning machine is divided into two sampling, and 100 pieces are taken consecutively each time The first time is to visually inspect the appearance of the packing box If the packing box is damaged, it is unqualified; the third time is to inspect the qualified products If the inner packing materials are damaged, insufficient or missing, they are unqualified The qualified rate of packing shall be calculated by the sum of the secondary unqualified products, and the qualified rate of packing shall not be less than 98% For the qualified rate of 98%, this index is not what the pharmaceutical companies want, but a little lower For a cartoning machine with an actual production speed of 150 boxes / min, the number of unqualified cartons per shift is up to 1440 For these unqualified cartons, one person / shift is also required to deal with them, which requires not only unpacking and reloading, but also wasting cartons Compared with manual cartoning, 98% of cartoning machine's qualification rate is slightly lower To improve the actual productivity and qualified rate of the cartoner is the premise of the application of the pharmaceutical factory Through the above analysis of the actual productivity and qualified rate of the cartoner, we can see the responsibility of the cartoner manufacturer and the cartoner Although the quality of the two aspects has been improving in recent years, it is far from the expectation of the pharmaceutical factory users A problem has to be raised here, that is, the quality of the box making If the quality of domestic machine-made box is not good, it will not help to use Zui good imported box loader From the data we have now, we can see that foreign cartoning machines eat "roughage", while domestic machines have a little better compatibility with cartons The limitation of cartoning machine to the inner package hinders its popularization According to the author's research on the cartoning machine for many years, the technical difficulties of small size, soft properties (such as plaster paste) and composite cartoning of several inner packages in the cartoning machine are high Zui However, the current situation of most domestic cartoning machine students only adapts to the single type and limited size and shape of the inner package The requirements for the package in standard 4.2.2.2 (JB / t10640-2006) are shown in Table 4 (1) as for the paste tube installed by the cartoning machine, the shape specification of the inner packing tube can only be within Φ 16mm-Φ 32mm, and generally it cannot operate normally if it is lower than Φ 16mm For example, the production speed of a company's cartoning machine is 50-100 boxes / min although the applicable range of its inner packing specification is Φ 13mm-Φ 35mm, its use speed can only be 50 boxes / min when the inner packing specification is Φ 13mm When it is lower than the specification of Φ 13mm, it can not be packed This is caused by the "broken box" caused by the fact that it is difficult to align the book and the hose into the carton (2) generally, the contents of the cartoner can only adapt to the hard materials When encountering the soft materials such as soft bags of granules and plasters, the cartoner can't pack them Fortunately, the existing domestic manufacturers can build the cartoner similar to the soft materials At the same time, because of the particularity of soft inclusion, the speed of soft inclusion should not be too fast (3) in addition to the instructions, the cartoning machine is generally only suitable for the packing of single inner package, but this form of packing is far from meeting the needs of diversified modern pharmaceutical production Although there are a few manufacturers with solutions for different varieties of composite packaging, and it has been successful However, this kind of box loader can only be made by 3-5 companies in China The quality problem of the domestic box loader is a classic Zui machine in the packaging machinery Many of its actuators are inseparable from the delicate mechanical actions If there is a quality problem in the four links of the manufacturing, design, assembly and configuration of the machine, it will lead to the instability of the machine operation (1) manufacturing quality In a sense, the box loader Zui is a complex machine, which includes machine, electricity, gas, light and other technologies In terms of the execution process, it eats "fine grain" However, the current overall processing level of the pharmaceutical equipment industry is still at the level of the 1970s, so it is difficult to process high-precision parts The usual manufacturing technology will cause the accumulation of assembly error, execution error, instability of such equipment at high speed and high scrap rate (2) design quality In the past few years, the research and development of cartoning machine is still in the stage of mapping imitation, which has not yet risen to the rational research of key mechanism The original error of mapping can not reflect the tendency of "instability" of movement at low speed Once entering the medium and high speed, there will be incongruity and "instability" between operating mechanisms These reflect the difference between domestic cartoning machine and imported products The key to solve the problem is theoretical secondary design (3) assembly quality There are many adjustable structures in the box loader, but the key to the success or failure of the normal operation of the box loader lies in the reasonable manual debugging At present, the level of debugging technicians in pharmaceutical equipment industry is difficult to compare with other industries, and the real qualified technicians are more From a certain point of view, no matter how good the design is, if there is no good assembly and debugging person, the box loader can only succeed in half (4) configuration quality The operation synchronization and detection control of modern cartoning machine depend on the control elements such as electricity, gas and light The quality of control element configuration determines the accuracy of control Different configurations will present a "vast difference" situation In terms of configuration, if the servo motor or stepping motor with high quality, stable operation and high positioning accuracy is used for driving, and if the servo motor with advanced and reliable sensor, encoder and motor is used as a whole, its actual effect is different from that of general configuration.