DESIGN QUALIFICATION CARTONING MACHINE HI CART (BLISTER PACKING)

CARTONING MACHINE HI CART (BLISTER PACKING)

The machine performs the following functions:

Storing of pre-broken cartons in flat form in the carton magazine.

Picking up the cartons from carton magazine.

Opening / erecting the carton.

Closing one side.

Loading Leaflet.

Loading product

Closing other side.

The machine consists of the following main stations:

Carton loading magazine.

Carton pick up.

Carton chain.

Leaflet chain.

Product chain.

Product transfer mechanism.

Carton Loading magazine

This consists of adjustable guides in which different sizes of pre-broken cartons can be loaded.  The guide adjustment is to be done manually, with the help of handles.

Carton Pick up

This arrangement picks up the carton from the loading magazine and transfers it to the carton chain.  Cartons are picked up with the help of a vacuum.  The carton is not picked up if the product or leaflet is missed.  This consists rotary drum pick-up sucker arm, vacuum pump, and vacuum valve.

Carton Chain

The carton chain holds and carries the carton while it gets opened, filled and closed.  This is continuous motion chain.  The carton opening and closing linkages operate in synchronisation with chain movement.  The chain is in two sections, one fixed and other adjustable.  This adjustment takes care of different carton widths.

The chain carries in 3 versions, two chain, three chain and four chain.  These 3 types are based on the 3 ranges of carton it can handle once the machine is built for a carton type (i.e. 2 chain or 3 chain or 4 chain) it can handle that range of cartons only.  The machine can not be converted to other type of chain configuration.   The subject machine is 3 chain machine.

Product chain

Products to be packed are carried on this continuously running chain and they are loaded into cartons at the pusher station.

The chain has pocket angles (cell angles) mounted on it.  The product is carried between these angles.  The distance between the cell angles is adjustable to handle various widths of product.

All automatic product transfer mechanisms are mounted along this chain.

The product chain also is made in two sections, one fixed and the other adjustable.

Carton discharge

After the carton is closed, the same is carried between two belts and discharged.  This can be collected in a bin or a conveyor.

Empty carton rejection system –

This system is provided to detect and reject empty cartons from the line. A sensor senses the product’s presence in the carton.  If the product is found missing in any carton, that particular carton will be ejected with the help of a pneumatic cylinder and prevented from going into the production line.  This ejected carton is collected in a separate bin.

Embossing station

This station is used to give batch code embossing provisions on the carton. The metallic stereos are fixed on the stereo roller and the carton flap is passed through the stereo roller and pressure roller to get the impressions of stereos on the carton flap.

Leaflet folding and transfer

This attachment is provided to fold a flat leaflet and insert it into the carton.  This station is provided after closing the bottom flaps and before loading the product into the cartons.  There are folding plates and turning plates in the leaflet folding machine with which several folds can be done as per the specifications of the customer and agreed by vendor. After folding, the leaflets are carried by belts and inserted into the cartons.  The synchronization of the folding unit to the cartooning machine is done.

PLC Description

This is the operator control panel for operating various systems like mode selector key (inch / run), vacuum pumps and monitoring and setting the various parameters.

PLC DETAILS:

Model – FX on 40MT-DSS, 24 inputs & 16 outputs, Mitsubishi, Japan ,All inputs are 24 VDC supply.

MMI DETAILS:Model – E300

Make- Beijers, Sweden. (Supplied by Mitsubishi)

Input supply – 24 VDC +/- 10%

Display – 4 line display

The operator panel was developed to satisfy the demand made for operator and machine communication.  The various devices can be monitored and PLC data changed through the screens in E100.  It is equipped with a dynamic indication alarm .

Purpose of Machine: The purpose of the cartoning machine is to carton pack, unit products automatically into cardboard cartons.

DESIGN QUALIFICATION

TABLE OF CONTENT

1. Objective
2. Scope
3. Responsibility (Client and manufacturer)
4. Machine description
5. Technical specifications and make of sub-components/bought-out items.
6. Details of Utilities
7. Identification of components for calibration
8. Material of construction of all components
9. Safety features and alarms
10. FAT procedure
11. Change control procedure
12. Qualification Document report approval
13. Appendix

OBJECTIVE:

To design, engineer, and supply the Cartoning Machine HI CART (Blister Packing) as per the URS and to ensure that it complies with the Scope of Supply.

To prove that each operation proceeds as per the design specification and the tolerances prescribed there in the document are the same at utmost transparency. The validation procedure is set for complete satisfaction of the customer & building confidence of the user in the machine.

The scope of this qualification document is limited to the Design Qualification of  Cartoning Machine HI CART (Blister Packing). This qualification document is part of a validation activity for the Cartoning Machine HI CART (Blister Packing).

SCOPE:

RESPONSIBILITIES

CLIENT

To check and approve the design qualification.

MANUFACTURER

To design, engineer, and provide the complete technical details of the equipment about its design qualification viz.

Machine overview,

General arrangement drawing.

Specifications of the sub-components/bought-out items, and their make, model & quantity, and backup records/ brochures.

Details of Utilities,

Identification of components for calibration

Material of construction of all components

Brief process description

Safety features and alarms

To facilitate the client for the Factory acceptance test of the machine at their works/ site.

To confirm the safe delivery of the equipment to the user site.

To ensure that no unauthorized and/or unrecorded design modifications shall take place. If at any point in time, any change is desired in the mutually agreed design, the Change control procedure shall be followed and documented.

To ensure the proper installation and commissioning of the equipment.

TECHNICAL SPECIFICATIONS:

 TECHNICAL SPECIFICATIONS OF COMPONENTS & SUB- SUB-COMPONENTS USED / BOUGHTOUTS

Part B = Sub-Components / bought-out items

 Details of utilities 

IDENTIFICATION OF COMPONENT FOR CALIBRATION 

In the Cartoning Machine HI CART (Blister Packing), the following components need calibration. They shall be calibrated during/ before installation of the equipment at the site:

1. Vacuum Gauge (Carton pick up, transfer & prebreaking)
2. Vacuum Gauge
3. (Carton pick up, transfer & prebreaking)
4. Vacuum Gauge (Leaflet folding)
5. Pressure Gauge (2 Nos.)

MATERIAL OF CONSTRUCTION

SAFETY FEATURES

All the electrical components, which have a high voltage, are covered with proper cover.

All the electrical / electronics components are mounted in a fully enclosed cabinet. This provides proper safety from live parts.

All moving parts are covered with proper guards with interlocks for some guards.

All necessary guards are provided with safety switches and interlocks. In case of removal of the guard, the machine will stop instantly.

Two emergency switches are provided in the machine, one at operator panel and other at discharge end of the machine.  Once it is pressed, machine will stop instantly.

Overload interlock is provided at pusher station.In case of any jamming during pushing, this interlock will actuate and machine will stop instantly.

All motors are connected through overload relays.In case of overload or jamming in the motor side or drive side, this relay will trip the motor and machine.

Any of the electrical phase failure or phase disconnection, single phase disconnection, single phase preventor unit will trip the machine instantly.

All electrical parts and full machine are earthed properly.

Operator handling areas such as sensors, operator panel, switches etc. are having low voltage (i.e. 24 VDC).

Prevention of oil contamination with product.

All main drive element e.g. motor and gearbox are mounted on machine base which is well below product chain and carton chain.

All the drive transmission parts such as chains and sprockets fall below the product and carton chain level.

Since the lubrication is not forced, the oil travelling upward is technically not possible hence oil contaminating the carton/product is not possible.

Primary pack contact surfaces:

The following are components which come in contact with product the primary pack :

Blister magazine: SS 304 Sheet Polished surface

Cell angle: Aluminium   Buffed

Chain plate: Delrin

Pusher: Aluminium Anodised

Following are components which come in contact with carton:

Carton magazine: S. Bright Nickel plated

Carton guides: S.  Buffed

Flap closers: S. Buffed

Carton chain: S.  Bright nickel-plated

Discharge conveyor belt: Rubber PU coated

LIST OF ALARMS/ INTERLOCK:

 FAT PROCEDURE

Factory Acceptance Test Procedure shall be as follows:

After the completion of the erection work of the machine, the client shall be requested to perform the factory acceptance test (FAT).

Client shall perform the FAT at the manufacturer site and record all the data in the prescribed FAT document as per the details given below:

1. Functioning of Machine operating panel with MMI
2. Interlocks and safety features are provided.
3. Details of major components fitted on the machine
4. Carry out product run and fill test criteria with product.
5. Check deficiency and corrective action taken report.
6. Fill up a chart of prerequisites of installation.  

CHANGE CONTROL PROCEDURE:

Change in the agreed design shall be addressed through the well-defined Change control procedure.

DESIGN QUALIFICATION REPORT 

APPENDIX

LIST OF ABBREVIATIONS

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