COMPLETE FILLING AND PACKAGING SOLUTIONS
Transcription
COMPLETE FILLING AND PACKAGING SOLUTIONS
C O M P L E T E F I L L I N G A N D PAC K AG I N G S O LU T I O N S RESPONDING TO THE WORLD’S PLANT MANAGERS, OPERATION MANAGERS AND ENGINEERS FOR NEARLY 100 YEARS Cozzoli Machine Company is a global leader in the design, manufacture, distribution, and service of precision cleaning, sterilizing, filling, and closing systems. Quality craftsmanship has always been the cornerstone of our foundation and we are dedicated to continuing that tradition of excellence. The products we engineer today are designed to take you beyond tomorrow, because at Cozzoli research and development doesn’t end when a system is successful. We continually update our methods and equipment, integrating fast moving technologies that shape the products we provide worldwide. I am committed to insuring that our products are designed and manufactured to the highest quality standards in the industry and dedicated to providing exceptional and dependable service. Joan Cozzoli Rooney President Cozzoli Machine Company MARKET SEGMENTS Pharmaceutical aseptic Pharmaceutical non-aseptic Cosmetic, health, beauty aids, personal care products Food, beverage, dairy Chemical, paint, industrial products 2 3 HOW WE GET YOU UP FASTER... AND RUNNING LONGER The most responsive team for all your packaging needs… Our expertise lies in the engineering and manufacturing of exceptional equipment, custom designed to your specifications for a multi-faceted turnkey operation. As a single source provider of individual components through full lines, our projects are defined by your individual requirements. Progressive Engineering… We utilize on-going technologies with design features that save time in product changeover and enhance productivity. Some examples are: • The use of the latest PLC’s makes operation easier than ever, allowing the operator to With a combined sixty years of work experience, Mario Della monitor and adjust volume, speed, and Fortuna and Morris Bekerman are two of the most respected technical experts in the industry. They represent the quality container size. and loyalty of employees at Cozzoli Machine Company. • Equipment upstream and downstream can be controlled from the same control panel, ensuring a smooth running, integrated line. • No-tool changeovers save time when changing product or container size. This capability reduces set-up time and increases throughput particularly when running a wide variety of products and containers. Value Added… Cozzoli will meet the specifications and level of automation you require with machinery of the highest integrity. We’ll test and fine-tune your equipment in our state of the art 100,000 sq. ft. facility before shipment to ensure the highest level of performance. A smooth start up eliminates costly delays. Unparalleled Service… We boast over three generations of experience in the design and manufacture of precision equipment matched with peerless dedication to technical service. When your line is down you need fast service. Cozzoli’s highly trained field service technicians travel the world, providing factory-direct assistance to protect your investment. Extensive Parts Inventory and Customer Service… Regularly scheduled preventative maintenance minimizes downtime and assures trouble-free operation. We maintain an impressive inventory of spare parts and are ever ready to assist you. You are just a phone call or fax away from receiving prompt, courteous attention from a Cozzoli customer service representative who will immediately process your request. From designers and fabricators to engineers and expeditors, sales agents and representatives, customer service representatives and service technicians, our dedicated staff will ensure that you receive the most productive solutions with unsurpassed support. Dependability… The quality machines we build today, just as those built and still operating since the 1900’s, demonstrate the value that Cozzoli Machine Company places on reliability. Rugged construction and dedicated workmanship you can depend on contribute to an efficient, smooth-running operation. 4 FILLING METHODS Fill-to-Level Fill-to-level fillers are especially suited for thin and foamy products (such as cleaning solutions). The fill-to-level fillers compensate for variations in container volume while retaining cosmetic fill accuracy. All fill-to-level fillers operate in the same principles as illustrated: gravity, pressure, and vacuum. Peristaltic Pump Nothing but the tube touches the fluid, eliminating the risk of the pump contaminating the fluid or the fluid contaminating the pump. The complete closure of the hose, which is squeezed between a shoe and the track, gives the pump its positive displacement action preventing backflow and eliminating the need for check valves when the pump is not running. Time Pressure Time pressure filling is accomplished by controlling the flow of the product through the tubing. The product stays in the manifold that feeds the tubes. A computer calculates the product flow time needed based upon manifold pressure, nozzle size, and target fill volume. Diaphragm Pump Diaphragm pump fillers are suited for corrosive chemicals, abrasive materials, and delicate liquids (blood, insulin, and plasma). This completely enclosed system eliminates air bubbles on small fills and features accurate repeat fills. Piston (industrial and aseptic) Piston fillers are ideally suited for filling a diverse range of products. These fillers are ruggedly designed yet precision built for long trouble free operation. Product viscosities may range from 1 to 100,000 centipoises and above. Rotary Time Pressure Time pressure fillers are well suited for filling heavy viscosity products. The nozzle is open to the product for a specified amount of time to achieve proper fill volume. Proper fill is dependent on three critical areas —— time of fill, pressure of product flow, and filling speed. Vacuum Powder This totally enclosed system removes the possibility of product contamination. Fill volume of each piston can be independently adjusted during operation. Two to sixteen fill stations are available. Multiple dose fills are made possible by simply setting the microprocessor. Product loss due to dusting is virtually eliminated. COZZOLI MACHINE COMPANY TEL (732) 564-0400 FAX (732) 564-0444 WWW.COZZO LI.CO M 5 LAB, PILOT, AND SMALL PRODUCTION Outstanding Features of Cozzoli’s Heavy Duty Lab Equipment Compact size - Designed for clean rooms or industrial settings and is ideal for labs or small production facilities. Plug and play - Easy to set up and even easier to use; plug in and connect to a bulk supply container. Easy to clean and sterilize - All parts which come in contact with the product are fabricated of 316L stainless steel. Easy to disassemble for cleaning and sterilizing. Suitable and designed for autoclaving, steam and/or gas sterilization. No “o” rings or gaskets. Built to last - Our small production machines are made to last for decades and built to handle any factory setting including those of food, cosmetic, chemical, and paint facilities. Highest level of performance - Designed for rapid changeover of parts to handle different products and containers on the same unit. Equipment available: Ampule hand sealer, screw capper, powder filler, liquid filler, washer, air cleaner (not shown), bench model single valve piston filling machine (BMSV), and mini BMSV (not shown) Bench model single valve (BMSV) piston filling machine with pedestal option. Washer Liquid filler Ampule hand sealer Screw capper Powder filler 6 PHARMACEUTICAL PRODUCTION (SPEEDS OF 600+ PER MINUTE) Washing Stringent regulations require strict compliance. Cozzoli’s versatile air cleaning and washing systems offer ease of operation and simple changeover, making compliance both direct and cost effective. Sterilizing Cozzoli depyrogenation tunnels feature unidirectional air flow, process temperature progression curves, and significantly reduced sterilization times. They provide the repeatable accuracy necessary for successful validation, qualification, and reliable production capacity. Controllable and reproducible process parameters simplify validation. Other features include safe zone pressure balance, automatic container density control for better temperature stability, friction-free container transport, and easy access to the tunnel interior for cleaning and maintenance. Filling Cozzoli provides continuous motion fillers with speeds up to 600+ containers a minute. Our fillers perform with outstanding accuracies of +/- 0.5% of fill volume or better. Production and cost saving features include compact size and quick and easy changeover. All liquid contact parts are made of 316 stainless steel and medical grade silicone to accommodate sterile requirements. Check Weighing The Cozzoli check weigher is the pharmaceutical industries’ state of the art system and uses magnetic force restoration type weighing technology. This technology provides high speed/high precision performance. The system consists of a tare weight unit, a gross weight unit, and controls that identify and store in the memory the net weight of each bottle, simultaneously transmitting this information to the printer. Additionally, the controller will send a signal either to the reject system and/or the filler for fine fill adjustment. The alarm will send a signal either visually (light tower) or audibly (buzzer) any time a gross weight is over or under pre-set limits. Stoppering This high-speed stopper placement machine is capable of full or partial insertion of a variety of stoppers into round bottles and uses smooth, continuous motion to complete its function. Elimination of intermittent mechanical motion makes high-speed placement and part handling attainable. These systems have a no tool changeover, make up and back up detection, PLC controls, jog mode, and sanitary “wipe-down” cGMP design. By adding optional equipment, i.e., make up and back up controls, the machine becomes fully automated, making it usable with filling and capping equipment by means of up and downstream transfers. Vision Inspecting Vision inspection at speeds of more than 600 containers per minute brings production throughput to a new level with our vision system. You can inspect 100% of your products and ensure that your shipments are defect free. Eliminate inspection personnel, fatigue factor, data collecting, and recording. Crimping The final component to the Cozzoli filling and stoppering systems is the continuous motion rotary crimper. Uniquely designed, it is capable of speeds of 600 + per minute and has the ability to test and record the seal pressure of every closure. Automatic vial height adjustment is provided for easy operator changeover and also is a safeguard against adjustment errors. Trayloading Utilizing the latest technology in robotic automation, the Cozzoli tray loader is designed for placing vials into either three or four-sided trays for lyophilization. Featuring a contemporary design with a stainless steel exterior, it is low, compact, and built to maximize laminar airflow effectiveness where class 100 conditions must be met. Vials can be loaded in straight, staggered, or “N minus 1” patterns easily selected from the electronic control and display panel. Barrier Isolation Technology Barrier isolation technology offers cost savings over traditional cleanroom technology, and provides better sterility assurance, contamination control, and safety. 7 INDUSTRIAL PRODUCTION Versa capper Rotary piston filler Filling Whether you need volumetric, fill-to-level, or time/pressure (versa fill) filling, Cozzoli has the right machine to meet your requirements. Our rotary and in-line fillers handle an array of products of diverse viscosities (1-100,000 centipoises) and different size containers measuring from fractional ounce to five-gallon units. We incorporate the latest technologies into our designs on a constant basis ensuring time savings in product changeover and enhanced productivity. Flush-in-place capability is available for our rotary piston and fill-to-level fillers. This allows liquid contact parts to remain intact on the machine during the flushing process. Our rotary fill-to-level series accommodates a diverse range of low and high viscosity products using vacuum, gravity, pressure, or a combination of these filling methods. Rotary piston fillers are fully automatic machines that accommodate a wide range of containers and products of most viscosities at high production speeds of 600+ per minute. High-speed time/pressure fillers are especially well suited for filling heavy products such as peanut butter, relish, lotion, shampoo, industrial grease, and glue. All rotary fillers can be combined for filling and capping in a monoblock design providing you with a compact, space-saving, and cost-efficient combination that is easy to operate, change over, and maintain. Fill to level filler Rotary fill to level Capping In-line The Versa Cap is a straight through friction disc capper designed to handle a wide variety of cap shapes and sizes with minimal changeover time required. The Versa Cap can be built in combination with any hi-speed rotary fillers in a monoblock design providing compact, cost-efficient operation. The Versa Cap accommodates threaded caps, snap-on caps and over-caps as well as plugs. Rotary Torque controlled for precision capping of a wide range of container shapes and sizes, the multi-cap rotary capper can be built in combination with any hi-speed rotary fillers in a monoblock design, providing a compact cost-efficient operation. Rotary fillers can accommodate threaded caps, snap-on caps and over-caps as well as plugs. This extremely versatile and effective machine is designed to handle caps up to 70mm in diameter at a speed of more than 600 containers per minute. Time pressure filler Monoblock COZZOLI MACHINE COMPANY TEL (732) 564-0400 FAX (732) 564-0444 WWW.COZZO LI.CO M 8 COZZOLI UNPARALLELED, INTEGRATED LINES: ACCURATE. DURABLE. FAST. DEPENDABLE. ASEPTIC FILLING LINE • 600+ per minute • Full check weighing • Vision inspecting • High accuracy INDUSTRIAL FILLING LINE • 900+ per minute • Fill any viscosity • Filling methods for any industry • High accuracy 9 SAMPLE FLOOR PLANS FOR INTEGRATED LINES ASEPTIC FILLING LINE • Washing/sterilizing • Filling • Sterilizing • Capping • Checking/coding GLASSWARE WASHING/STERILIZING FILLING UNSCRAMBLER AC CHECK WEIGHER AND FILLER STERILIZING INACTIVATION CHECKING CODING STOPPERING EMERGENCY STOP START GUJ TRATS YCNEG REME POTS BOWL SPEED MANUAL JOG AUTO STOP MAIN SPEED R YNAPMOC ENIHCAM R MACHINE COMPANY START STOP EMERGENCY WASHER STOP SPEED CONVEYOR BOWL VIBRATORY SPEED MAIN STERILIZER TRAY LOADER UNSCRAMBLER CRIMPER ACCUMULATOR CAPPING EXTERNAL WASHING DECARTON DOSING EMERGENCY STOP PANELVIEW 600 ALLEN BRADLEY 7 4 1 8 9 5 6 2 3 0 PURGING START STOP F1 F2 F3 F6 F7 F8 F4 F5 F9 F10 INDEX SPEED 40 VACUUM 60 80 20 R MACHINE COMPANY 0 100 6.25 [158.75mm] ASEPTIC FILLING LINE • Washer • Tunnel • Unscrambling/accumulating • Powder filler • Stoppering • Crimping EMERGENCY STOP START MAIN SPEED CONVEYOR SPEED STOP VIBRATORY BOWL R MACHINE COMPANY HEATER BANK WASHER STERILIZER UNSCRAMBLER POWDER FILLER STOPPERING CRIMPER ACCUMULATOR 10 ASEPTIC FILLING LINE • Washer • Sterilizer • Unscrambler • Filling and Stoppering • Crimping • Accumulator • Tray loader STOP START 6 EMERGENCY STOP SPEED 5 4 3 7 2 8 1 9 10 WASHER STERILIZER UNSCRAMBLER FILLER & STOPPERING CRIMPER ACCUMULATOR 0 TRAY LOADER INDUSTRIAL FILLING LINE FILLER CAPPER LABELER UNSCRAMBLER ACCUMULATOR COZZOLI MACHINE COMPANY TEL (732) 564-0400 FAX (732) 564-0444 WWW.COZZO LI.CO M 11 COZZOLI CUSTOMER SERVICE When Jack Schrum needed a machine for high volume glass ARTICLES AND A redesigned sixth bottling line at spirits manufacturer and co-packer U.S. Distilled Products provides a 60-percent increase in speed over existing lines. TESTIMONIALS SPIRITS SOAR WITH NEW LIQUOR FILLING/LABELING LINE ampule sealing, he didn’t consider any other company. He knew that By Anne Marie Mohan, Senior Editor minimizes changeover on the filler by limiting to three the number of bottle sizes run: .750 mL, 1 L and 1.75 L. "We could do all of the sizes if we wanted to,” explains Rowland, “but w e feel that it’s not efficient to fill the smaller bottles, because the volume is just not there.” Due to the clean-running operation of the line’s new MRM/Elgin-supplied filler, products of all viscosities are run, from water-thin spirits to thick and sugary cordials. But the largest volumes, notes Rowland, are in the spirits. Cozzoli had the capability to do what he wanted. When asked about his experience with Cozzoli’s Customer Service, he answered, “Service has been excellent – we think the world of Sam Alexander, (Technical Service manager at Cozzoli.) Since we are located nearby, Sam can stop in anytime – one of those 30-year employees that does whatever we need. Service and products are what keep us coming to Cozzoli.” —from an interview with Jack Schrum of Rutgers University and member of ISBER Just as wine depends upon the perfect proportion of acidity and sweetness, fruit and oak, and alcohol and flavor to create a well-balanced taste, U.S. Distilled Products Co. (USDP) is placing more emphasis on a balance between short and long product runs, and own-brand versus co-packed products to sustain its thriving business. Establishing a bottling facility in 1981 for its own alcohol product lines, the Princeton, MN-based company later uncorked its capabilities for other brands. Today, with a recent brand acquisition, USDP has come full circle. “We’re trying to focus on a balance between our own brands and our relationships with other companies, so that we can keep our plant’s capacity at a very high level,” says Todd Geisness, general manager and executive VP of USDP. Traditionally USDP’s strongpoint had been in producing small runs of 100 to 200 cases of bottled liquor. Thus, it equipped its six filling lines with versatile machinery that allowed for quick changeovers. But, as its brands grew in popularity, so did its run lengths. This evolution, coupled with the competitive nature of the bottling market drove USDP to install a completely new line, outfitted to accommodate larger-volume runs quickly and efficiently. Today, USDP typically runs three lines per 10-hr day, four days per week, maximizing the efficiencies of both its low- and high-speed equipment to meet various filling needs. To take advantage of the new line’s speed, USDP 12 The heart of the ne w line is 51-nozzle MRM/Elgin Husky 5 RFL rotary fillto-level liquid filler that allows for gravity, pressure, or combination gravity/ pressure filling. This versatility was vital to USDP’s equipment selection, given the company’s large range of product viscosities, and container sizes and materials. “To change over from one mode to another is fairly simple and can be done in about ten minutes,” says on top of the machine. Notes MRM/Elgin, “The inherent difficulty of filling liquids like cordials is the sugar content. When drive parts are below the fill level, the sugar can get into the mechanism where it’s hard on cams, bearings and other machine parts.” Rowland adds that he was also impressed by the filler’s ease of maintenance, made possible by a centralized lubrication system, and the quick changeover enabled by tool-less changeparts. Changing over from one product to another, while retaining the same bottle size, is a 20-minute process, he notes, while a full changeover can be accomplished in an hour and fifteen minutes. “If you look at the amount of nozzles we have, that’s pretty quick,” he says. On average, the filler runs at a 230- to 250-bottle/min rate, for a total of 15,000 to 20,000 cases/day. According to USDP’s Geisness, after just more than a year and a half in operation, the new line is virtually bug-free and is delivering “greatly increased productivity.” Installing the ne w line to increase our production capability enhanced our flexibility, and this has allowed us to become more efficient. And, obviously, the more efficient you are, the more competitive you can be when bidding on a contract. There is no doubt that our ability to be competitive has resulted in a lot more inquiries from potential customers.” Reprinted and condensed from PACKAGING DIGEST® October 2002. Copyright © Reed Business Information, a division of Reed Elsevier, Inc. By Jack Mans, Plant Operations Editor Biomune Company is a leading U.S. manufacturer of vaccines for the animal health industry. With headquarters in Lenexa, KS, the company produces more than 50 US Dept. of Agriculture-licensed products and serves customers in 37 countries. Its manufacturing sites utilize state-of-the-art equipment and standard operating procedures in the production of live and killed vaccines. In June 2005, Biomune installed an integrated packaging line consisting of a Model UT 36 rotary unscrambler, a Model VR2S-10 in-line monobloc filler/stopperer and a BT 15 dual automatic tray loader, all from Cozzoli Machine Co. (www.cozzoli.com), to run small vials ranging in size from 5 to 20 cc. The line is installed in a Class 100 clean-room. "Cozzoli wasn't highest or lowest on our list when we started thinking about this project," says director of manufacturing Bill Krehbiel. "We looked at several other machines, but we have three other Cozzoli machines in our plant, and we have had good experiences with them, so we decided to stick with Cozzoli." Glass vials, which have been sterilized by hot air, are delivered to the line on trays, from which a worker manually pushes them onto the rotary unscrambler table. The unscrambler delivers the vials single-file to a conveyor that transports them to the monobloc filler/stopperer. A slight plastic protrusion on the side of the conveyor near the monobloc unit causes any vials that have fallen over to drop off the edge of the conveyor into a bin. At the entrance to the intermittent-motion monobloc unit, the vials enter a feedscrew mounted beside the conveyor. The screw extends through the filling zone of the unit and spaces and controls the vials for filling. The filler runs 10 vials at a time, and the feedscrew stops during the filling operation, holding the vials while the filling takes place. The nozzles descend, creating a bottomup fill. The nozzles rise in conjunction as the product is being dispensed, so as not to create any splashing or foaming. The feedscrew starts up again to discharge the filled vials and deliver the next group of vials beneath the nozzles. Each nozzle is served by a dedicated positive-displacement piston pump that includes a suck-back feature to eliminate dripping. Both fill volume and the amount of suck back can be adjusted manually to optimize the fill accuracy, which is typically in the 0.5-percent range. SMALL-VIAL FILLING FINESSE In response to the question of why they selected Cozzoli to manufacture vial washers for them, Steve Panneta of Alk Abello replied, “We usually choose manufacturers based on experience and reputation. The feedscrew ends at the discharge of the filler, and the vials enter a starwheel that conveys them beneath the stoppering wheel. Stoppers are delivered from an overhead hopper down a track to the wheel. The rotating stoppering wheel picks up the stoppers, rotates in synchronization with the starwheel and pushes the stoppers into the vials. The unit can insert lypholization stoppers, which have a slot in the center and are pushed only part way into the vials and regular stoppers, which are pushed all the way into the vials. The filler/stopperer incorporates an upstream sensor to ensure there are enough vials on the conveyor entering the unit and a downstream sensor to detect unstoppered vials. The unit is controlled by a programmablelogic controller that stores the recipes for all of the products run on the line. Vials leaving the stopperer continue on the conveyor, which makes a rightangle turn and delivers them to the Model BT15 dual-tray loader. An infeed system directs containers onto the tray loader, where rows of vials are pushed onto three-sided trays. This unit also incorporates an A-B PLC, which counts the number of vials pushed onto a tray and diverts the vials to the adjacent tray when the first tray is filled. A worker then replaces the filled tray with an empty tray, and the process is repeated. "The Cozzoli equipment is of high quality and built to last, and it is relatively simple to set up and operate, since most adjustments do not require tools," says Krehbiel. "Cozzoli also has an excellent service department, so if we do need service, they take care of us immediately." Reprinted and condensed from PACKAGING DIGEST® March 2006. Copyright © Reed Business Information, a division of Reed Elsevier, Inc. We’ve been doing business with Cozzoli for 25 years, and have had excellent success with them from the beginning. Cozzoli advances their styles and we’ve advanced along with them. We buy a particular piece of equipment; a vial washer made to order. We haven’t had to research competitors in a very long time; we’ve stuck with Cozzoli because of their exceptional products. We are a repeat customer – third machine over the years – and we are extremely happy.” —from an interview with Steve Panneta of Alk Abello and member of ISPE 13 A HISTORY OF INNOVATION AND PERSONAL ATTENTION 1922 1930 1953 1983 2003 Cozzoli Machine Company (CMC) is founded. CMC develops first aseptic filler CMC designs first monoblock CMC develops first line CMC purchases MRM/Elgin Corp. expanding the company’s business into the food, cosmetic, and industrial markets CMC opens new 100,000 sq. ft. facility in Somerset, NJ ST C E R T I F I CA EM TI ON SY 1919 IS O 90 01 14 :2 0 0 0 1895 1926 1943 1974 1999 2008 Elgin Manufacturing Company is started and develops first industrial filler CMC receives first patent and is awarded first prize at the Belgium International Exposition CMC provides fillers to vaccinate US troops CMC is named Drug Packager of the Year CMC becomes first US based packaging machinery company in our market segment to achieve ISO 9001 certification President Frank J. Cozzoli poses with the outstanding Cozzoli staff outside of the Somerset, New Jersey headquarters. FOR MORE INFORMATION PLEASE CONTACT: Cozzoli Machine Company 50 Schoolhouse Road Somerset, NJ 08873-1289 Telephone: (732) 564-0400 Fax: (732) 564-0444 [email protected] www.cozzoli.com COZZOLI AT A GLANCE • Application Analysis - Application Engineering - Product Testing • Product Design - Line/machine design • Manufacturing • Line Integration • Validation - Qualification - Verification • Installation • Parts & Service Genuine Factory Replacement Parts Maintenance Field Service Service Contacts FOR MORE INFORMATION PLEASE CONTACT: Cozzoli Machine Company 50 Schoolhouse Road Somerset, NJ 08873-1289 Telephone: (732) 564-0400 Fax: (732) 564-0444 [email protected] www.cozzoli.com ST C E R T I F I CA EM TI IS O 90 01 :2 0 0 0 ON SY -
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