Suppository Processing
Suppository Processing
Suppository Filling and Sealing Machine: The Ultimate FAQ Guide
1. What is Suppository Filling and Sealing Machine?
Suppository filling and sealing machine is an automatic pharmaceutical machine that you can use in filling and sealing suppositories.
Apart from filling and sealing suppositories you can use the suppository filling and sealing machine to:
- Preparing base materials or shell of the suppositories using PVC, PVC + PVDC, PE or PVC + PE material
- Filling of medicinal value into suppository shells
- Cooling the entire component of suppositories
- Cutting suppositories into different sizes and lengths
- Sealing the suppository thus making it ready for other batching and distribution procedures
Suppository filling and sealing machine
2. What is Suppository?
A suppository is an advanced method of delivering drugs into the body.
Suppository
You will introduce suppositories into the body through other openings including the vagina, rectum, or urethra.
You will find suppositories in different shapes and small sizes such as cone shapes and spheres.
3. Why use Suppository?
You will use suppositories because it is a more direct manner of administering drugs to the area with the problem.
Implying that, suppositories dissolve and release that active drug at the point where it will be most effective.
For instance, in case of a rectum infection, you will use suppositories to treat the rectum more effectively.
4. What are the Benefits of Suppository Filling and Sealing Machine?
Using the suppository filling and sealing machine will draw you the following benefits:
Suppository filling and sealing equipment
· Suppository Filling and Sealing Machines are Automatic and use PLC programming
The production mode of the suppository filling and sealing machine is fully automatic.
It also has a programmable logic controller which you can use to compliment easy operations of the system.
You can easily monitor all the operations of the machine from one unit.
What’s more, the machine an automatic alarm system that will go off whenever there is a problem with the system.
· High Rate of Production
The automatic nature of the machine allows you to produce the suppositories in a quick and most effective manner.
You will be able to produce approximately 9000 to 13000 pieces of suppositories when you are using the machine.
The rate of production will also depend on the type and size of the suppository filling and sealing machine.
· Easy to Run and Operate
With the help of machine user interface, you can go through the straightforward process of controlling and operating the machine.
You will eliminate the need of hiring extra employs to assist in the operations of the machine.
Besides, the machine comes with an easy to maneuver control box and a complete touch screen for easy operations.
· Precision and Accuracy
You will use the machine to fill the exact amounts of suppository content.
Volumetric pumps and nozzles firmly fit the mold cavity openings thus prompting precise and accurate filling.
You will reduce the chances of spilling and wasting the content of the suppositories.
· Wide Range of Applications
You can use the machine in different applications since it has several operating techniques that will fit different industrial requirements.
· Adequate Fluid Reserve Capacities
The machine has a large capacity storage tank that stores the suppository fluids.
You will save a lot of energy and stress of having to refill the tank regularly thus slowing the production process.
· Requires Minimal Supervision
All the procedures of the machine are automatic and with the help of the PLC you will not need regular supervisions.
All you have to do is key in the parameters you need and then let the machine proceed with the production process.
· Occupies Reasonable Space
The suppository filling and sealing machine occupies an economical amount of floor space because of the size.
The whole component is sizable and only occupies a particular floor space.
Apart from that, you will only require a meter of space around the machine to adequately carter for the operations.
· Regulated Speed Cooler System
Different suppository contents such as drugs require different degrees of cooling temperatures at varying cooling speeds.
The machine is flexible enough to allow different cooling rates at varying speeds depending on the suppository drug content.
· High Quality Machines
The machines are of very high quality with proper certifications thus reducing the requirement of acquiring certification permits.
It comes with the certification documents from various organizations and certification bodies intact.
Some of the certification bodies include FDA, cGMP, CE, ISO, and CPGP among others.
· Minimizes Wastage of Materials
With the accurate nature of the machine, you will eliminate the possibility of wasting any form of drugs.
Apart from that, you will be able to produce the suppositories according to the production specifications thus eliminating waste.
5. Which Industries use Suppository Filling and Sealing Machine?
You will use the suppository and sealing machine in different industries such as:
Semi-automatic suppository filling machine
· Pharmaceutical Industry
The pharmaceutical industry uses the suppository filling and sealing machine for continuous releasing and packaging of suppositories.
· Food Industry
You will use the suppository filling and sealing machine in adding and packaging food supplements and nutrients into the suppositories.
It comes as a proper substitute for other pharmaceutical drugs and capsules which had certain side effects.
· Cosmetic Industry
The cosmetic industry uses the machine to laden the cosmetic suppositories with the cosmetics that perform different functions.
The most common form of pharmaceutical suppositories are the vaginal suppositories and the rectal suppositories.
6. What is Virginal Suppository Filling and Sealing Machine?
You will use the vaginal suppository filling and sealing equipment in the production of vaginal suppositories.
The machine is capable of formulating vaginal suppositories in solids and oval shapes.
Despite the fact that it produces hard suppositories, the drugs are capable of quickly dissolving when in use.
7. How does Rectal and Urethral Suppository Filling and Sealing Machine compare?
You will need a urethral suppository filling and sealing machine for the sole purpose of producing urethral suppositories.
It produces the urethral suppositories which are often muse or small in size.
The machine is capable of designing the suppositories in different forms including 200, 500, and 1000 micrograms.
On the other hand, you will use the rectal suppository machine in the sole production of rectal suppositories.
It is flexible and has molds that form the suppositories in round shapes with bullet tips.
The rectal suppository machine produces rectal suppositories that are 1-inch long.
Apart from the above descriptions, you can use the rectal suppository machines to perform the following:
- Administration of medication including antibiotics, respiratory treatments, analgesia and sedation.
- Treatment of anal hemorrhoids or pruritus and prevention of constipation.
8. What are the main Parts of Suppository Filling and Sealing Machine?
Efficient functioning of the suppository filling and sealing machine will depend on the following main parts:
Suppository filling and sealing equipment
· Feeding Part and Film Unwind System
This system forms the first unit of the suppository filling and sealing machine thus allowing entry of raw materials.
The film in use in this system is available in three main types which include PE, PVC and PVC + PE.
It consists of a transfer fixture and the film release plate where you will place the film.
Apart from that, it has a transmitting fixture acting as a trolley for relaying the film.
Generally, the feeding part allows the entry of the films necessary for the formation of the molds.
Unwinding system
· Forming/Molding Part
This is the part where the suppository shells form or mold.
It consists of a guide wheel responsible for rolling the packaging compound to the formation area.
Additionally, it consists of heating molds, blowing molds or butt molds, responsible for shaping the shells of the suppositories.
It also has base line cutting equipment for shaping and cutting the suppository shells
Forming part
· Filling System
This system consists of the filling pump, capacity material bucket, stirrer, circulating pump, and agitator.
Filling pump has plunger pumps that mechanically drive the filling material into the capacity material bucket through a certain force.
Capacity material buckets usually serve as temporary storage for the materials that you intend to fill into the suppositories.
The sandwich layers of hot water are responsible for maintaining the temperature during the operations.
This is the system that will ensure that you fill the materials into the suppository molds.
Filling system
· Cooling Tank System
It consists of air cooler fans, water chillers, and double cooling tunnels for sufficient cooling of the suppositories.
The two cooling systems provide a wide surface area for sufficient cooling process to occur.
Water chillers provide low temperatures which the cooling fans will automatically distribute.
The systems work together to maintain the operation temperatures between 8 and 16 degrees centigrade.
· Closing and Sealing System
These parts are responsible for additional heating of the system with the intention of closing and sealing the suppositories.
It has a pneumatic sealing box that will automatically close and seal the suppositories.
· Marking and Printing System
This is the part of the machine responsible for inscribing the necessary marks and symbols on the suppositories.
The main marks and symbols to inscribe include manufacturing and expiry dates, and the batch number.
· Cutting and Trimming Elements
This is the part responsible for cutting and trimming the elements according to the right size.
· Electrical Control Cabinet System
Electrical system
This is the point where all the power you need for controlling and operating the machine originates from.
It includes the PLC communication module, human computer interface, sensors and transducers, and warning devices among other key components.
Other parts of the suppository filling and sealing machine include:
- Dotted Cutters
- Resistance Heating Rods
- Sealing rings and Cables
- Air joint bearings and belts
- Suppository molds
9. How does Suppository Filling and Sealing Machine Work?
The suppository filling and sealing machine works through the following stages:
· Stage One: Film Unwind Stage
At this point, you will choose the type of materials that you will use such as PVC or PE materials.
Depending on the film material that you choose, the film moves from the unwind plate through the transfer structure.
With the help of a clamp the film unwind will relay the PVC to the molding section of the machine.
· Stage Two: Molding and Formation
The film will go through several sections of the molding and formation stages.
The stages include preheating of the film, heating, forming and blowing casts.
At this point the shells will assume the desirable shape of the suppositories.
With the help of dotted line cutting blades and triangle side knives, the machine will cut the shapes precisely.
· Stage Three: Filling Step
After the formation of the shells, you will fill the homogenous materials which is ready at 80 degrees centigrade.
The machine will load the empty suppositories to the three to six filling terminals.
The dosage on every suppository ranges between 1 gm to 5 gm depending on the dosage requirements.
It allows a margin of error of plus or minus 0.2 grams.
The efficiency an accuracy of the machine allows an error of plus or minus 0.1.
As this happens the heaters maintain the heat as the mixers continue with the mixing procedure of the content.
All the remaining portions recirculate the system until it receives the proper amount of fills.
· Stage Four: Cooling
At this stage, the machine regulates the temperature using the double cooling units, water chillers and air coolers.
In the cooling tunnel, the suppositories cool down completely through the assistance of the cooling apparatus.
Remember to maintain the cooling temperatures between 8 to 16 degrees centigrade for an efficient cooling process.
· Stage Five: Sealing
The sealing of the suppositories is possible through the sealing tails.
At this stage, another sequence of reheating occurs after which a pneumatic system embeds a seal on every element.
· Stage Six: Printing Stage
This is the part where the ink jet printer will print the manufacturing and expiry dates, and the batch number.
· Stage Seven: Cutting and Packaging
With the help of sharp cutting blades, the machine will cut the suppositories accordingly.
You can program the machine to cut the number of suppositories at a particular speed.
It then proceeds to the cartoning machine which places the suppositories into the right packets.
It completes the process by closing the packages completely for storage and distribution purposes.
10. What is AluAlu Suppository Filling and Sealing Machine?
AluAlu suppository and filling machine is responsible for filling and sealing suppositories that are highly sensitive and highly hygroscopic.
It fills and packages suppositories are sensitive to light with the right packages except for the barrier plastic films.
In many cases, the machine uses AluAlu foils to help in the packaging of the highly sensitive suppositories.
11. Why Choose SaintyCo Suppository Processing Equipment?
You should choose SaintyCo suppository processing equipment because of the following reasons:
- It delivers state of the art equipment with integrated technology from the best technological manufacturers.
- The machines guarantee you with automatic filling, shaping, and repairing of the shape hypothermia.
- The production processes of SaintyCo suppository processing equipment is swift, accurate, and easy to monitor.
- The machines also have one of a kind counting systems, precise filling capability, efficient cooling, durable, and continuously functioning parts.
- You can also use the machine to produce different types of suppositories such as plant based suppositories.
- The machines have different supporting mechanisms for enabling the suppository filling and sealing process to run smoothly.
SaintyCo has different suppository equipment that bare the above characteristics.
Suppository filling and sealing equipment
12. How can you Install Suppository Filling and Sealing Machine?
You can install the suppository filling and sealing machine by going through the following steps:
· Step One: Ensuring Proper Installation Requirements
In this stage, you have to confirm if the following factors are in place:
i. Relevant humidity ranging between 30 to 60% and room temperature between 18 to 28 degrees centigrade.
ii. Space allocation with at least one meter of space around the machine.
iii. Ground installation free from excess vibration by leveling the framework using appropriate anchor tools.
· Step Two: Assembling Stage
The machine has five disjoint parts that you have to assemble correctly by incorporating to achieve viable machines.
Connect the filling station to the cooling panel after which you will connect the sealing parts with opposite ends.
Make sure that all the connecting parts are tight with firm grips.
Install the material barrel and then connect the cooling system to the chiller.
· Step Three: Installation of Power Connections
After locating the electrical box, connect the electrical cable to the aviation plug and make the three face connection in order.
Regulate the voltage of power supply and the working frequency by following the installation manual.
Fix the air connectors while maintain the air pressure at 0.6 mph to 0.7 mph
· Step Four Connecting Supplementary Equipment
This includes certain parts such as chillers which you can fix by connecting the chiller to the cooling shaft.
Ensure that the inlet and outlet pipes of the chillers and cooling shafts have proper connections.
All the installation procedures of different machine are on the installation manual.
13. How do you Troubleshoot Suppository Processing Machine?
The most common problems that you may experience include the system errors and mechanical errors.
You can determine the problem in the machine by trouble shooting the machine.
Here are some of the problems that you may encounter during the operations of the machine and how to solve them:
· Machine Refuses to Start
You can sort this by:
i. Confirming if all components are connected well
ii. Verification of the electrical and gas connections
iii. Firmly screwing the emergency stop switch in case it is lose.
iv. Checking the display for any irrelevant information before contacting technician for assistance.
· Failure of Machine to Start in Automatic Mode
You can sort the problem by:
i. Resetting the machine
ii. Ensuring the emergency stop switch is in place
iii. Check the display and act according to the instructions on the display by seeking technical advice
iv. Confirming if the sensors are working properly with the right signals.
v. Configuring the machine settings into the programmed settings
· Failure to Reset the Machine
You can solve the problem by:
i. Stopping the machine through the emergency stop button before restarting it.
ii. Confirm if the sensors are working well.
· Heating Issues
You can sort the problem by:
i. Confirming if the thermostat is working properly
ii. Checking if the heater terminals are in contact with the mold of the machine
iii. Replacing the heating wire in case it is faulty or broken
iv. Confirming the electric heater is short circuited.
· Monitor Malfunctions
This can be in the form of improper display of the functions.
You can solve the problem through:
i. Checking if the communicator is in proper attachment with the power control system and fix it.
· Slow Speed of Production
The speed of production can intermittently decline or fail.
You can solve this by:
i. Confirming the pressure system for any blockage on the pneumatic system.
ii. Confirm if the seal ring is in place or may have some damages and then fix it.
14. Is CGMP Compliance Important for Suppository Processing Units?
Yes, current good manufacturing practices are very important for suppository processing units.
It ensures that the machines keep up with the current trends in the manufacture of suppositories.
15. Can you Recommend Material for Suppository Filling and Sealing?
Yes, there are different materials that you can use in the suppository filling and sealing machine.
Some of the materials that you can use include the PVC, PE, PVC + PE, or PVC + PVDC rolling films.
The filling material will, however, depend on the industry with which you are using the machine on.
16. How do Specify Suppository Filling and Sealing Machine?
Whenever you intend to purchase a suppository filling and sealing machine you will use the following specifications:
- Production capacity which might range between 3000 to 6000 pieces in an hour
- Dosage error ranging between plus or minus 2%.
- Dosage per granulation ranging between 0.5 – 5 grams in every granulation.
- Form of suppository you intend to make such as torpedo, duck mouth, and bullet form among others.
- Number of plates for shearing granulation
- Source of power which can be three phase AC 380 V
- Power of the entire machine which can be 7.8 kw.
- Air pressure of the machine assumable at 5kg/cm3
- Consuming gas tolerance
- Overall dimensions such as weight of the machine.
17. Which Suppository Filling Line does SaintyCo offer?
SaintyCo offers the following suppository filling and sealing lines: