Your goal is to find a quality suppository filling and sealing machine that is cost-effective, durable, and sturdy, contributing to the success of your pharmaceutical company.
Then it would help if you read this guide. A suppository filling machine is discussed in detail, from the equipment’s function and design to its advantages and potential uses.
If you want to find out more, read on!
Suppository Filling and Sealing Machine
An innovative and modern way to provide medication to the body is through a suppository. This refers to the practice of giving medications through methods other than the oral route, such as the urethra, rectum, and vagina.
It’s common for suppositories to be tiny and cone- or sphere-shaped. When taken orally, it dissolves and melts, releasing its therapeutic properties into the body.
Traditional ways to give medicine, like injecting, swallowing, or putting drops in your eyes or ears, are very different from using a suppository. Most pharmaceuticals look and feel the same in terms of form and function. They may be in the shape of tablets, liquids, powders, etc.
It is important to understand and be aware of the causes behind this new idea of pharmaceutical consumption. Suppositories come in a variety of forms, as is seen from the way we use them. Rectal, vaginal, and urethral suppositories are the most common.
These are some of the reasons why suppositories are widespread;
It is a different method of administering drugs than orally. Before, oral admission was the most usual and conventional technique. Some medications, however, cannot be passed in this manner. Some may be very difficult to swallow because they taste terrible and are unpleasant to the tongue.
Because of suppositories, several drugs poorly absorbed by the stomach may now be administered safely. Certain medications have a high disintegration barrier, which may explain why they are difficult to digest in the stomach. Suppositories are beneficial for this since the medication is immediately and smoothly delivered. The full contents of the container may skip the digestive system and reach the bloodstream directly.
Suppositories dissolve and release their contents into the body. They immediately reach the target body part and have a therapeutic effect.
Suppositories, on the other hand, are highly concentrated therapies that target a particular location. They efficiently cure many medical concerns, such as hay fever, fever, pain, bacterial and fungal infections, hemorrhoids, etc. Moreover, the use of suppositories is often beneficial for the following medical issues:
- Persistent vomiting after taking medication.
- If medication dissolves quickly in the stomach.
- If the medicine loses its therapeutic efficacy during digestion.
Meanwhile, a suppository filling and sealing machine is, thus, a fully automated, advanced pharmaceutical equipment that performs not one but three vital functions inside a single mechanical enclosure. A suppository packaging machine work on the following;
- Helps prepare the suppository shell from PVC, PVC + PVDC, PE, or PVC + PE.
- Places the medication in the suppository shells. Cools and cuts them to the lengths or sizes you specify.
- Seals the suppository, preparing it for further mixing and delivery.
Suppository filling and sealing machines are more often referred to as manufacturing lines. Each step, from forming the shell through filling, chilling, sealing, and finally cutting, is performed by a single machine.
Here’s how the suppository filling and sealing machine breaks down into components:
- Thermoforming begins with a single unit winding two reels of PVC or PVC + PE film into the desired shapes and sizes. A continuous strip of shells leaves the unit when it is ready.
- The filler equipment injects pharmaceutical mixes into cavity-formed strip cavities.
- The third chiller is in charge of chilling and setting the content mixture in the molds. This part often has a larger length to allow for optimal cooling.
- The last machine successfully plugs the holes in the batches, prints the necessary marks or codes, knurls the suppository strip, and then cuts the finished items to the specified sizes.
Applications
There are a variety of applications for this suppository filling and sealing machine. Its methods are technical and complex. The applications include:
Pharmaceutical Sector
The pharmaceutical industry is the principal application for suppository filling and sealing machine—the constantly expanding and evolving field. Constant release and medication packaging in suppositories are standard to meet these rising demands. As a result, pharmaceutical businesses throughout the world are quickly embracing the use of suppositories as a method of providing critical pharmaceuticals.
Suppositories also contribute to the advantages of other routes of medicine administration. As was previously mentioned, suppositories of all three main types (rectal, vaginal, and urethral) are effective against a wide range of potentially fatal conditions. Bisacodyl, hydrocortisone, hydromorphone, etc., are only a few examples of medicinal suppositories.
Food Sector
In the food processing sector, a suppository-making machine is a valuable tool. It’s important to remember that suppositories are ideal for both healing and wellness.
Suppositories may include vitamins, herbs, and nutraceuticals. They often replace the usage of prescription medications or lessen their adverse reactions.
Rectal suppositories containing nutrients are equally absorbable as pharmaceutical suppositories. The nutrients go directly to the heart through the inferior vena cava and the many blood veins in the rectum. In addition, rectal suppositories provide a safe and effective delivery system. This is because it is a great area to absorb nutrients. After all, its PH is neutral, and it doesn’t have any buffers. Extremely potent nutrients not advisable to take orally are provided through food suppositories.
Cosmetic Sector
Filling and sealing machines for suppositories are widely used in the cosmetics business. Products are cosmetics if they have no medicinal value and are used only for aesthetic purposes, such as washing, smelling nice, and hydrating the skin. Vaginal and rectal suppositories are the most common types of cosmetic suppositories.
In this situation, cosmetic vaginal suppositories are the best way to clean deeply, stop odors, and keep the skin moist. These cosmetics help maintain a natural balance, give a feeling of fresh energy, and eliminate a strong feminine smell.
The same way for rectal glycerin suppositories, which can forestall the onset of constipation. In those three areas, you may safely use the suppository packaging machine.
Benefits
There are beneficial effects throughout the manufacturing process. It is advantageous not only in producing fully-functioning suppositories but also in terms of other functions. This is so that manufacturers may continue to improve the equipment as technology advances. The suppository machine’s functionality and usability will develop over time, becoming suitable for broader usage. These are some advantages you may anticipate once you start using the equipment.
✅ Highly Automatic and PLC-Programmed
Suppository manufacture is automated using a PLC that works in tandem with fully automatic filling and sealing equipment.
The built-in testing functions of the PLC provide thorough line-level monitoring. In the case of a malfunction, the system will sound an alarm and display the issue in a synchronized manner, enabling a technical operator to identify and resolve the issue rapidly.
✅ High Level of Production
The higher production efficiency is a significant advantage of this equipment. Certainly, the fast pace of manufacturing overshadows any other benefits. You should have between 9000 and 13000 of your products within an hour.
✅ Easier to Use and Maintain
In the pharmaceutical business, this equipment is among the most user-friendly options. All of its procedures are simple and require nothing in the way of manual effort. The only need is a proper setup of the machine.
The instructions for setting up are part of the package. It also has an efficient control panel and a comprehensive touchscreen.
✅ Precision Reduces Waste
Shells for suppositories are always filled with care. During the filling stage, a volumetric filling pump with nozzles for adding content fits snugly into the hole in the mold.
The content level and volume are adjustable. You carry out this action in the PLC control interface. As a result, apart from precise cutting, there is no danger of substance spilling or waste.
✅ Wide Applications
The suppository manufacturing process offers a variety of uses. That is, its applications and procedures serve not just a single industrial sector but also others. Keep in mind that this equipment offers quality services to the food, cosmetic, pharmaceutical, and pharmaceutical industries.
✅ Sufficient Material Storage
The bulk of this packaging machine includes massive fluid storage tanks. The larger storage tank will save the time and effort of constantly filling the vessel whenever the contents run out. With a tank of this size, you may easily store up to 80L of material for discharge.
✅ Less Monitoring
The PLC allows full automation of all processes in production. To use the software, you need to enter the necessary settings and then sit back and wait for the manufacturing process to finish.
✅ Use Only Functional Floor Space
When people think of the manufacturing system, they picture something complex. Rather, the entire equipment may only take up a decent amount of space. Also, you only need about 1 meter of room to move around the machine and do all the tasks you need to do.
✅ Speed-Controlled Cooling
Various medications will need cooling at varying speeds. Certain substances may take a while to solidify, while others take a short time.
As a result of the difference in cooling rates, it is necessary to regulate the cooling process. When you use this technology, you have speed flexibility. The temperature controller guarantees that the contents solidify consistently and acceptably.
✅ Complete Certification
There is no need to stress over securing multiple operating certifications or completing a lot of paperwork. You will get the proper paperwork in its original condition.
Many regulatory agencies shall provide their stamp of approval to the suppository filling and sealing machine. Assumed accreditations include CGMP, CE, FDA, CPGP, ISO, and many more.
✅ Low to No Waste
To put it another way, this is one well-tuned machine. To that end, you may be surprised that the technology used to fill and seal suppositories assures that no raw components are compromised.
Moreover, any power outage or mechanical failure throughout the operating process will result in material waste. Additional major benefits of this method include the following:
- Speed modification is now possible with flexible cutting.
- For the production of suppositories, it is compatible with a variety of polyvinyl chloride (PVC), polyvinyl chloride (PVC + PE), and polyethylene (PE) material structures.
- Adjustable mixing speed in a container. All of the components are thoroughly mixed thanks to the industrial-strength mixer.
- The mechanical components are stainless steel, which eliminates the possibility of rusting and corrosion.
Machine Types
Vaginal Suppository Filling and Sealing Machine
This machine creates vaginal suppositories. The mechanism makes this sort of suppository solid and oval. They turn into a liquid state when placed in the vagina and warmed by the body.
Suppositories are easier to insert into the vaginal canal using a plastic applicator. Suppositories for the vaginal area are effective against a variety of genital conditions.
- Contraceptive vaginal suppositories are extremely useful for family planning.
- The yeast infection vaginal candidiasis is quite common, and they help cure it.
- Prevent dryness by maintaining appropriate vaginal moisture and optimal PH.
- Always use the vaginal suppositories’ specifications as input while using this kind of equipment.
Urethral Suppository Filling and Sealing Machine
This device also has the unique capability of manufacturing urethral suppositories. Standard urethral suppositories, known as MUSE, are very little, often no bigger than a grain of rice. More precisely, its length ranges from 3mm to 6mm, and its diameter is 1.4mm. Alprostadil used to treat erectile dysfunction, is automatically dispensed into the shells.
Alprostadil produces an erection by relaxing the smooth penile muscles, allowing more blood to flow to the penis. Moreover, the suppositories are available in three distinct machine-designed sizes: 250 µg, 500 µg, and 1000 µg. Each size is determined by doctors or other qualified experts operating under close observation.
Rectal Suppository Filling and Sealing Machine
Rectal suppositories are the only focus of this unique machinery. The suppositories it creates have a uniform round shape, and the machine’s tip is shaped like a bullet, making it a very versatile device. The typical structure of a suppository is taken care of by the molds used to create the shells. The rectal suppositories are 1 inch in length.
Therevac, Dulcolax, and Magic Bullet are the most common rectal suppositories. So, what is the significance of rectal suppository filling machines? With the help of this equipment, the rectal suppositories provide the following functions:
- Avoid constipation.
- Provide medicine such as antibiotics, analgesics, respiratory treatments, and sedatives, among other things.
- Relieve itching or anal pruritus, often known as anal hemorrhoids.
Machine Components
Film Unwind and Feeding Section
The first component of the machine is the film unwinding and feeding section. To begin the process, the primary unit receives the input of all primary materials. The film is split into two parts.
Also, depending on your choices and accessibility, the films can be one of the three types: PVC, PE, or PVC + PE. The film unwinding mechanism includes a film release plate and transfers attachment. The first is to apply the film to the plate. The transmitter or clamp would function as a trolley to relay the film. As the film used to make the molds enters here at the beginning of the process, this section is called the feeding portion.
Molding or Forming Section
This is where shaping suppositories occurs. A wheel here acts as a rail, guiding the packaging material to the forming zone.
At the first clamp point in the forming station is the heating mold. In the second clamp position, the preheating cavity takes shape in the third clamp position. In the slots that run perpendicular to the forming chamber, you can also see the butt molds that go with the blowing molds.
These molds shape suppository shells. Base finishing and dotted line cutting tools assist in shaping and cutting shells at this stage. This makes excellent shells.
Filling Section
Many procedures are taking place in this part, as well as different equipment. It includes the filling pump, a high-capacity material bucket, an agitator, a stirrer, and a circulation pump. This mechanically pushes materials into the filling pump’s bucket with pressure. In addition to around ten material injectors at the base of the siphon, many plunger pumps greatly facilitate the filling pumps’ function.
Material buckets are often a short-term storage facility, and homogeneous mixing happens at this point. All of these devices improve the filling process.
Hot water sandwich layers heat bucket materials to your desired temperature. Whereas an extra electric heater raises the temperature to 80 °C. The bucket’s agitators and a stirrer with a changeable speed are both motor-driven as well.
A recirculation pump is helpful for evenly dispersing heat and keeping the substance at a consistent temperature. The material supply between the filling pump and the barrel is now additionally supported by the circulation pump. It is at this stage that the molds are filled with the materials.
Cooling Tank Section
Here you will discover the component devices such as water chillers, air cooler fans, and double cooling tunnels. Having two separate tunnels for cooling allows for a lot of exposed surface area. It’s sizable, so the suppositories can be stored there for a sufficient time while cooling.
The cooling tubes are where the suppository strips go to chill off. Water chillers give low temperatures to additional cooling fans. These variables sustain an 8–16 °C temperature in this zone.
Closing and Sealing Section
The preheating mold receives cooled suppository strips from the sealing tail. The suppositories’ tails are sealed with a pneumatically operated box.
Marking and Printing Section
The inkjet printer prints four lines on each strip suppository set. You may change the markings here to suit your tastes. The distinguishing features are the batch number, expiration date, manufacturer, date of manufacturing, and batch number.
Trim and Cut Mechanism
The top margins of the suppository strips are trimmed once they enter the sharp cutting part. The suppository is then cut with sharp blades. The suppositories are placed into individual packages using an automated cartooning machine.
Control System & Cabinet
The electrical control system is an essential part of the machine as it controls the flow of power and electronics. Below are some of the components in the electrical and control cabinet:
PLC: Duty-bound to transmit and coordinate all data and information in the machine’s software.
HMI: This includes electronic devices with graphical user interfaces, speech recognition software, and touch screens.
Each device will help you connect with the machine, which then converts your data into the machinery’s operating mechanism.
Sensors and Transducers
In this setting, transducers such as ultrasonic, temperature, piezoelectric, and pressure sensors play crucial roles.
Electrical, optical, mechanical, chemical, thermal, auditory, electromagnetic, and other forms of energy are only some of the many that may be converted and manipulated by the transducers.
- Sensors
- Screen and controller
- Electrical warning device
- SIEMENS, primarily PLC and HMI
- Auto-electronic entry or limit switches.
- Thermoregulators and thermoforming system
- Air processing equipment using electromagnetic valves
Some of the machine’s other spares are as follows:
- Dotted cutters
- Suppository mold
- Sealing rings, cables
- Resistance heating rods
- Air joints, bearings, belts
Working Principle
❶ Film Unwinding/Opening Phase
Users have the option of using PVC or PE film materials. The clamp motion pushes the PVC/ PE/ PVC + PE from the film unwind in the plate and through the transfer setup. The PVC is relayed into the molding portion via the clamp structure.
❷ Molding & Formation Phase
The long film strips pass via the guiding wheels and into the molding process—many different formation molds, including pre-heating, heating, forming, and blowing casts.
At this stage, the substance takes on the ideal shell cavity, a form suitable for storing suppository material. Then, a triangular side knife and dotted line cutters accurately cut the resulting shapes.
Furthermore, the shaping process on the bottom border of the cavities begins. These actions continue throughout the formation phase before sending the fully formed shells into the following phase.
❸ Filling Phase
After the material has been heated uniformly to around 80 degrees Celsius, it may fill the shells. Keep in mind that there is anything from three to six filling pumps. After loading a batch of suppositories strips, it is transferred to the next phase.
Typically, the dose of each suppository ranges from 1 gm to 5 gm, with an allowable error of ±0.2. This filling machine is fully automatic, so the filling accuracy should be under ±1%. About the remaining raw materials, there is no need for concern. It is continually heated to the right temperature by an electrical heater.
To create a homogeneous mixture, the mixing motor continues to mix the raw ingredients. Next, the nearest circulator allows the raw material from the injector transport to reach the filling station.
In the meanwhile, the leftovers are recycled for use in the next filling cycle. The complete batch of suppository strips advances.
❹ Cooling Phase
These suppositories enter the cooling tube as whole strips. Double air conditioners, air conditioners, air coolers, water chillers, and cooling fans all contribute to keeping the temperature at a suitable level.
The suppositories are at a suitable temperature by the tunnel’s cold water and the quadruple condensers’ cooling air. The temperature is controlled between 8 and 16 degrees Celsius so the suppositories can properly cool and solidify.
❺ Sealing Phase
Then, the cooled suppositories go into the tails for sealing. This technique transfers the suppositories into the preheating mold for a second warming operation. A pneumatic sealing device then applies a seal to every suppository.
❻ Printing Phase
After sealing the suppositories, the relay strips transport them for printing to the inkjet printer. Products have print codes such as:
- Manufacturer
- Batch number
- Manufacturing date, etc.
After the printing process, the products move on to the next station in a continuous loop.
❼ Cutting Phase
The last stages of production include passing the almost final product between two sharp blades. From the strip, a set of six suppositories is cut. You may alter the number of grains you need to cut to more or fewer depending on your preferences. Just input the relevant command using the interface, and the system will do so for you.
Packaging
A cartooning machine receives the cut row and quickly packs the suppositories into packages at a rate of around 40 per minute. The packing equipment then seals the packages after filling. Once filled, the packing device then closes the packages. Now, you may enjoy your perfectly packaged, finished suppositories.
All the steps we’ve gone through thus far—forming, filling, chilling, sealing, cutting, printing, and packaging—follow a pattern.
Keeping a high degree of safety under control is critical throughout the production process.
- One must be knowledgeable about the machine’s operational mechanics and its more basic modes of functioning as part of the production process.
- One must first investigate the many alternatives available by these modes of operation before you can complete all of the available modes of operation.
- The operator may also make changes and switch between different modes of operation for the device.
It is, of course, a straightforward affair depending on the cases of your manufacturing. These modes are;
Reset
To ensure the machine functions correctly, you must first check that all its parts are in the correct positions. This is the same condition for a quick start.
So why would you want to restart the process? Because it is an essential step after the operation of the molding die, whether in manual, semi-automatic, or automated mode. To do a reset, follow these steps:
- Check that the machine properly connects by plugging in all the power and signal cords.
- Then, turn the main power switch on.
- The control must be in the “Manual” position for the process to be manual.
- The last step is to turn the reset dial.
Automatic
The PLC allows the device to function fully automatically, performing each step in a sequence. If you wish to do this procedure, then;
Make sure the machine properly connects before proceeding. Otherwise, you must handle the connection first.
- If appropriately connected, switch on the power button.
- Install the roller with care and precision.
- Press the reset button now.
- Then, hit the start button.
Manual
Choose the “manual” option from the menu on the touchscreen panel. A new window appears with a submenu. Once again, press any function key to start the process.
Emptying
This practical approach drains the coolant strip placed in the tunnel of all suppositories. You may complete the procedure by emptying. However, the formation and filling stations would halt anytime you ran out. As a result, the guiding wheel rapidly moves all of the suppositories from the cooling tunnel to the sealing section and cutting blades until they are depleted. Here’s how we should go about doing the emptying.
- Before doing anything further, make sure the machine is connected correctly.
- Press the main button to start.
- Choose “Manual” from the manual/automatic switch.
- Turn the reset knob.
- Choose “Automatic” from the manual/automatic control.
- To begin, click “empty” on the touchscreen panel.
Installation
Installation is critical to any piece of equipment’s initial and continuous functioning. As a result, you should proceed with great care and adequately study the manufacturer’s instructions before trying to install the device. Here’s all you need to know.
☞ Humidity & Room temperature
You’ll get the most out of your machine if you put it in a certain kind of space or setting that meets these specifications. From 18°C to 28°C in temperature. Humidity: 30%-60%
☞ Space
Provide at least 1 meter of clearance around the machine for service technicians to work in.
☞ Installation on the ground
To avoid discomfort, your working space should be completely free of vibrations. No additional unique criteria or prerequisites are needed to construct the machine’s ground.
First and foremost, you’ll need to use the right-hand tools to ensure your installation’s structure is level. Ensure that the machine’s anchor bolts are adequately tuned to connect the machine’s various components correctly.
☞ Connections
The suppository filling and sealing machine have five independent components that must be attached correctly to operate. Although these components perform independently, they must work together to produce a working whole.
- Begin by connecting the filling station to one end of the cooling tube.
- Upon finishing, connect the sealing component to the cooling station’s other opposite end. To create a solid grip, flush all of your connecting parts.
- Now is the time to properly place the material barrel.
- Lastly, connect the cooling station and the chiller.
☞ Power Connection Installation
Electrical Connection
- The first step is to find the electrical panel.
- Next, connect the electrical wire to the aviation plug. The aviation plug is at the rear of the electrical box.
- Create the proper three-phase electrical connection.
- As with the instructions, adjust the power supply voltage and operating frequency.
Pneumatic Connection
- The first step is to open the door, and then you may connect the compressed air hose to the air hose in the forming frame. Keep in mind that the minimum diameter of the connection pipe you use is 14 mm.
- Keep the speed at about 0.6 – 0.7 mph. Adjusting the pressure gauge valve to the suitable reading is how you get the air pressure right.
☞ Managing auxiliary devices
The suppository filling and sealing machine includes auxiliary devices like chillers. We will concentrate on the chillers, which are essential in chilling the tunnels.
- Use two circulation pipes to connect the chiller to the cooling shaft. One pipe is to chill the water, and the other is to heat it.
- Following that, connect the chiller’s outlet and inlet pipes, as well as the cooling shaft.
- Lastly, connect the cooling shaft’s return pipe and the chiller’s intake pipe.
Troubleshooting
|
Problem |
Solution |
| The equipment will not start. |
|
| Does not start automatically. |
|
| Cannot be reset |
|
| The mold’s temperature doesn’t go up, or the shell can’t get hot. |
|
| The monitor is faulty. The data are not visible on the monitor. |
|
| The process becomes slow. Occasionally, manufacturing speed decreases. |
|
If you have any initial issues with this system, please refer to the above troubleshooting methods. You still could run across problems with these systems, and we may have yet to address them. But it’s best to contact a professional if you ever have a technical issue and need help fixing it.
Technical Advantages
✔ Interfaces or Touchscreens
This suppository filling and sealing machine has an easy-to-use touch screen. It has no regular crushing and is very delicate to the touch. Because it reacts to your touch, you won’t have to keep pressing or applying more force. In addition, the touch screen provides access to all necessary data and input instructions, including those related to the different system parameters (pressure, temperature, manual or automatic operating modes, etc.).
The induction touch switch gives you complete control over how the machine works. Production rates, for example, are adjustable by the user. You also have total control over the machine’s setup and may make any changes you see appropriate.
✔ Sensors and Photocells
The machines’ sensors, photocells, and optical fibers regulate the flow of power processing. Sensors and photocells, when linked together, rely heavily on feedback to relay data via a connecting device.
This input generates from the system’s functionality rather than the touch proximity detection capabilities. These sensors and photocells use the associated induction lights to perform their functions. To examine it, you must loosen or tighten the bolt suitably to adjust its placement. Remember that it should not be too distant or too near. As a result, you must appropriately configure and pick all of the sensors and photocells, as they’ll considerably impact the machines’ operation condition. Most of all, you must clean and examine these parts regularly to evaluate their status.
✔ Temperature Control
When in operation, the thermostat controls the machine’s temperature. With the touchscreen interface, you may adjust the thermostat settings as necessary. The thermostat will sound an alert if the workplace temperature rises over the user’s specified point. There are generally two kinds of sounds you could encounter;
- One that activates when the temperature drops below the set point.
- Also, for a higher temperature than the given amount.