Aspects of the IBC 150 that promote the efficient packaging of tablets in bottles

Efficient tablet packaging in bottles

The integrated monoblock architecture of the IBC 150 offers all the essential stations for the packaging of tablets in bottles. This line is highly automated, optimally linked, centrally controlled, and completely flexible. The basic model includes stations such as the bottle infeed, servo-regulated tablet counter, capping unit, and bottle discharge. Other elements, like a modular desiccant feeder for canisters or sachets, a weighing system, a camera system for tablet inspection, or a cotton wad feeder, can be integrated as required.

Advantages of the IBC 150 at a glance

Powerful

Format-free bottle transport for an uninterrupted product flow – from start to finish

Flexible

Great flexibility on account of the small number of format parts, fast format changeovers, and automated adjustment to a new bottle height

Scalable

Scalable performance: up to four counting modules and three capping units for added counting capacity or higher output, or a combination of both, for up to 150 bottles or 24,000 tablets or capsules per minute

Precise

One hundred percent counting accuracy with the Cremer infrared counting system

Reliable

Optional tablet inspection for maximum pharmaceutical reliability

Safe

Fully enclosed system for operator and product protection

Comprehensive

Servo-regulated capping system for the processing of all types of caps

Smart

Central, intuitive operation using the HMI SmartControl

Media Gallery: IBC 150 in focus

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Video

Bottle line IBC 150

Bottle transport
A format-free rake ensures intermittent-motion, guided, and uninterrupted bottle transport throughout the process – starting with the infeed, including desiccant and tablet feeding, and ending at the discharge. No congestion, no wedging, and no micro-stops or ramp-up phases.

Desiccant feeding
The Uhlmann bottle filler for solid dose products offers a modular feeder for up to three desiccant sachets (illustrated). Alternatively, the feeding of canisters is also possible. Dry-air and nitrogen flushing can also be integrated into the feeder as optional alternatives

Tablet counter and tablet feeding system
The IR counting system is a unique, linearly controlled tablet counter that attains 100% counting accuracy using infrared technology.

Capping unit
The IBC 150 has a servo-regulated capping unit suitable for all common types of caps and including monitoring of the closing torque. Rejection of bottles with incorrectly fitted caps, faulty induction foil, or desiccant in the cap.

IBC 150 with tablet counter and capping unit
Uhlmann applies the principle of module integration to form a centrally operated bottle line for the packaging of solid dose products: the IBC 150 with tablet counter and capping unit.

IBC 150 with desiccant feeding, tablet counter, cotton wad feeding, and capping unit
The IBC 150 line for solids in bottles can be optionally extended to include other modules such as a cotton wad feeder or a capping unit.

The packaging line IBC 150 with a single tablet reject function is able to eliminate individual damaged tablets before they are filled into a bottle. As an example, this means that only three tablets – instead of hitherto three bottles – are removed from the process.

Our Global Product Manager, Konstantin Gerbold, talks about world region-specific packaging demands & our production line concept IBC 150.

The IBC 150 handles up to 150 bottles or 24000 tablets or capsules per minute and is reset to a different bottle diameter in just six minutes.

IBC 150 in detail

Technical data at a glance
Max. output 150 bottles/min.
Max. counting speed 24,000 products/min.
Bottle volume 30 - 1,500 cc
Bottle diameter 25 - 125 mm
Bottle height 45 - 200 mm
Processable bottle materials HDPE, glass
Processable bottle shapes round, rectangular, oval
Processable solid dose products tablets, capsules
Product length 3 - 30 mm
Product width/diameter 3 - 20 mm
Counting accuracy 100 %

 

Bottle line IBC 150 for solids in detail

The IBC 150 is a pharmaceutically compliant line for tablets and capsules in bottles offering end-to-end packaging. A guided bottle transport prevents micro-stops, product jams, and wedged bottles. Uhlmann has used the monoblock architecture to integrate all the stations needed for a GMP-compliant packaging process. The line fills up to 150 bottles per minute – they can be round, oval, or rectangular. This makes the bottle filler for solid dose products the ideal solution to meet alternating requirements in the medium output range.


Fast format changeover with format-free bottle transport

The IBC 150 bottle filler for solids can be adjusted to a new bottle diameter in just six minutes. The small number of format parts makes this possible. Furthermore, the use of conveyor belts, which require more intensive cleaning, has been avoided for bottle transportation. A format-free rake is responsible for the intermittent transport. This opens up numerous options for the packaging of medicines to suit a variety of markets and target groups. The IBC 150 handles bottles 45 to 200 millimeter in height and 25 to 125 millimeters in diameter, and thus covers a wide range of formats. The maximum output is 150 bottles or 24,000 tablets/capsules per minute.


Centrally controlled

All the machine processes are controlled via SmartControl, a human-machine interface (HMI) with a touchscreen. The graphical user interface ensures intuitive comprehension. All format data is stored in the control system. Uhlmann can also link other machines and components to this user interface – if needed, also equipment from other manufacturers – thus creating an integrated and efficient overall system. This reflects the line competency of the Uhlmann specialists.


100% accurate counting with the IR counting system

In terms of technology and process reliability, the bottle filler for solid dose products meets high standards: the infrared counting unit handles tablets, coated tablets, caplets, and capsules, as well as special shapes (e.g., rhombus, octagonal). The IR counting system ensures 100% accurate counting.

The integration of a dedusting system for very dusty products is one additional option. Another is the incorporation of dry-air or nitrogen flushing. An optional camera system recognizes and reports errors regarding the shape, color, and type of product.


Tailored reliability

The line can be fitted with Track & Trace by Uhlmann to comply with statutory requirements. The system can, for example, mark the base of the bottles as they pass through the Bottle line IBC 150. Cameras scan the codes and store the information in the Uhlmann tracking database. The system for serialization and aggregation can, of course, be integrated to cover the entire line – the IBC 150, the labeler and cartoner, as well as the end-of-line packaging systems. The data can be accessed at all times and linked to the code data of the next-larger unit.

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A comparison of our bottle lines & labeler

  Max. output Max. counting speed Bottle volume Processable bottle shapes
150 bottles/min. 24,000 products/min. 30 - 1,500 cc round, rectangular, oval
240 bottles/min. 42,000 products/min. 30 - 950 cc round, rectangular, oval
180 bottles/min. (round), 165 bottles/min. (rectangular, oval) - - round, rectangular, oval

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