Intertech Technologies Pvt. Ltd.

The machine is composed of three parts, i.e. mechanical drive, purification by water and steam spray arrangement and Electromechanical control. Bottles to be washed move into the washing trough with stainless steel mesh conveyor-belt followed by cassette assembly from half body portion & move to various washing zones.. After certain washes by water and steam, ensuring the cleanliness is compatible with GMP regulations. Additional ultrasonic cleaning procedure according to the craft requirements. All mechanical drives are separated from washing zone.

OPERATION

Three-cycle rinsing allows flexibilities of various wash cycles such as fresh water, dematerialized water etc. as per the rinsing requirement of bottle. All the pumps are made of SS and all the water contact parts are made of SS 316 on a heavy base of SS structure.
In tunnel design is such that separation is maintained between feeding zone and discharge zone of the cleaned containers. All the mechanical drives are separated and isolated from the washing zone. Approved materials only are used for construction, together with a careful choice of components, thereby taking in to consideration all aspects of sanitation and consequence complying with the pharmaceutical G.M.P. requirements.
The quality of rinsing is ensured through 3 sets of inner and 2 sets of outer nozzles accurately placed to direct the jet at center of the bottle and the bottle comes out with water totally drained with minimum droplets of water.

SALIENT FEATURES:

• High-pressure spray nozzles ensure perfect wash of Bottles.
• Interchangeable wash sequences.
• Totally fabricated from SS Materials, including the basic frame.
• No change parts required for washing of round bottle saving time of change over. (Change Parts require for Flat bottles & if change of neck size.)
• All parts coming in contact with washing zones / jet are made from SS 316 materials.
• The machine suitable for handling washes of round and flat glass bottle (With help of change parts).
• Water re-cycling arrangement is possible as per customer’s need.
• Machine is totally rigid and with stands continuous operation for long working. Hours without any trouble. • Higher capacity centrifugal pump to wash bigger container.
• Third Tank & pump can be fitted (optional).

This machine is suitable for packing Bottles into cartons. It performs automatic fish folding, forming, opening & loading, batch numbers printing as well as tucking process. It adopts PLC Control, photoelectric supervision control for every parts. It has got inbuilt fault detection feature. This machine can be integrated with upstream filling & capping machine.

OPTIONAL:

• Feeding of leaflets or booklets
• All controls for automatic running
• Variable data (embossing, ink jet, laser, hot foil coding)
• Barcode reading of cartons and leaflets

The Liquid Syrup Manufacturing Plants are ideal tools for the pharmaceutical industry for the production of Oral Liquids. Majority of Liquid Oral Syrup are sugar based & this sugar syrup is prepared using hot mix technology. Broadly end product is wither a blend of various ingredients including drugs i.e. Cough Syrup, Health tonic etc. or dispersed phase of ingredients i.e. Antacids, Pediatric suspensions. Therefore designing of entire Liquid Syrup plant is done to take care of its versatility for both Blend & dispersed phase end product. Also quality is governed by level of automation & well GMP design of plant. Liquid Oral manufacturing systems comprises of equipment for automated sugar transfer, double jacketed and non jacketed vats for sugar syrup preparation, compounding / ingredient mixing and storage with product distribution piping. The range covers capacities from 500 to 15000 Liters with various options in top and bottom entry agitators for mixing and homogenizing of clear syrups and suspensions. We offer a range of precision engineered inverter syrup sugar solution, which have been designed after extensive study to automate and prepare continuous sugar syrup.

Liquid Manufacturing Plant consist the following equipments and accessories:

• Sugar Syrup Vessel
• Pre-filtration unit
• Manufacturing Vessel
• Filtration unit
• Storage Vessel
• Control Panel
• Product Piping
• Working Platform

BASIC DESIGN FEATURES & OPERATION

• Entire plant consist of a closed circuit manufacturing facility from feeding of Sugar / Water Phase to loading the Volumetric Liquid Filling Machine.
• The Sugar and Water, are load with vacuum system or by mechanical system or manually.
• The Sugar Syrup Vessel is supplied with high speed stirrer & electrical heating ( In small model ) / steam heating facility (In bigger size model ).The sugar syrup is prepared at required temperature & are transferred to Manufacturing Vessel by vacuum or by transfer pump.
• The product during emulsion formation is re-circulated through In-Line Homogenizer or Liquid Transfer Pump. (Optional Facility)
• The Pump also discharges the product in the Storage Vessel.
• The Storage Vessel is then taken to the filling area ( if it is small capacity ) and is connected to again Liquid Transfer Pump. Or Storage Vessel remain fixed ( In bigger size) & pump transfer the Liquids in the float tank which is connected with filling machine.
• The entire Plant can be operated by centralized operating panel by one operator.

SALIENT FEATURES

• The Plant is designed to be operated only by one operator and one helper to reduce cross contamination & higher automation
• All material transfers are done by vacuum or by transfer pumps.
• All the vessels are CGMP (paint free construction) with gaskets used are of silicon (food grade).
• All contact parts are of S.S. 304 quality material (SS316 provided on demand) & finished to class 4B (Mirror) finish and are crevice free.
• The entry of stirrer & high speed emulsifier are from top. In-line Emulsifier (as per customer choice) provided on demand. (Optional)
• All vessels are suitable for internal pressure of 1 Kg. / Sq. cm. and hence can be sterilized.
• All pipes, pipe fittings and valves are of SS304 / SS316 ( as per customer requirement ) seamless quality, internally electro polished, with tri-clover ended joints. Bottom valves are zero dead pocket type with pneumatic actuation also.

TECHNICAL FEATURES

• Completely Automated Process Cycles
• On line display of process parameters with P & I of Operating Systems
• Display of Fault messages
• Supervisory access code prevent unauthorized changes
• Detergent / Acid / Alkali dosing
• On Line PH, Conductivity, TOC Sensing
• CIP is designed in accordance with ASME BPE and EHEDG guidelines
• PLC-based, with Touch Screen MMI and SCADA Packages

PROCESS BENEFITS

• Validation process for cleaning of process equipment
• Lower Facility Operating Costs
• Minimal dismantling of equipment and piping
• Reduced turnaround time for cleaning
• WFI requirement for cleaning reduced significantly
• Exposure to hazardous activities or entry into tanks, is eliminated

OPERATING PROCEDURE :

1. FILL MODE :

For Tank 1

• Low level sensor will actuate to open Diaphragm valve fitted in purified water looping to supply water into Skid Mounted tank
• High level sensor will actuate to close Diaphragm valve fitted in purified water looping to stop supply water into Skid Mounted tank

For Tank 2

• Low level sensor will actuate to open Diaphragm valve fitted in purified water looping to supply water into Skid Mounted tank
• High level sensor will actuate to close Diaphragm valve fitted in purified water looping to stop supply water into Skid Mounted tank
• Note : Two separate Diaphragm valve in purified water loop will be provided for independent actuation as per the demand of tank 1 & 2.

1. HEATING OR MATURATION MODE

• Water in the Jacketed tank is heated to pre-set temp.
• Discharge of pump is connected to header of process tanks.

1. WASH MODE

• Water from any of two tanks, with pre-programmed recipe, will be allowed to pump into supply line
• Time & pressure is preset while deciding recipe of wash.
• After completion of time, Water from another tank will be allowed to pump into supply line.
• Adjusting pressure, valve actuation is done by PLC thru instrumentation provided into system.

The system consists of Cyclone Separator, Bag filter with Turbine Blower, and De-clogging arrangement, Structure stand, Bottom Butterfly valve at cyclone, Electrical control panel, pipe fittings, interconnecting pipes (options). It would be used to transfer powder from Siever discharge to Vertical Conical Blender.

PRINCIPLE OF OPERATION

The Scheme is a LEAN phase Conveying method. Actuation of the blower achieves a negative pressure in the entire system. Air is drawn into the Loop through the suction wand. High air velocity allows for simultaneous injection and conveying of materials, to the product disengagement chamber (CYCLONE SEPARATOR). The body of the equipment can be vacuumised and material is drawn in directly to Sugar Dissolving Vessel & any fines which are carried over gets trapped into the filter to the cyclone separator. These are discharged either on a going basis or at the end of the transfer cycle. In the Cyclone, air separates from the product due to break in the conveying velocity. Timer controlled sequential operation of the discharge valve allows for

--Vacuum break
-- Filter De-clogging
-- Product / Dust &Fines Discharge

The cycle is repeated till desired quantity of material is dispensed. In the current scheme the product will be directly drawn into the body and the carry over dust/crystals will be entrapped in the Cyclone. Normally flexible wand is manually put into the Sugar crystal storage bin & under negative pressure, Sugar is withdrawn thru Siever into Dissolver. All fibrous & other extraneous particle are sieved into Siever.

The system consists of

• A vacuum conveying system utilizing Roots Blower, Modular construction equipment
• Jet Air Wand with Air regulating Damper
• Jet Air Wand fitted with stainless steel wire mesh to stop foreign particles entry in to process.
• Entire transfer through electro polished pipe with curvilinear bends and isolating valves both manual and pneumatically actuated.
• Flexible pipe in PVC food grade with SS wire. Piping from Cyclone separator to Blower is in non compliance of food grade material
• Suitable filters pleated 5 micron in the product unloading chamber, pulse jet type, for insitute separation of dust from conveying media
• Root blower to create negative pressure for material conveying.

OPERATION

This Mono block type filling & sealing machine as name indicates is a combination of both Rotary Filling & Rotary Capping Machine. The filling principle is volumetric i.e. positive displacement of the product with piston and cylinder arrangement. The suction and discharge of product in / from cylinder is controlled by Rotary valves which are fitted on cylinder itself. Piston assemblies are fitted with square blocks which move in inclined cam track which controls the suction & discharge of material. Square blocks are moving up in inclined cam track. The product is transferred from main Rotary Tank to the cylinder assemblies. The cycle is completed in 180 degrees. While the blocks are moving down the cam product is discharged in bottles/containers. The volume of product to be filled is controlled by inclination of the cam track since stroke length is controlled by cam inclination, which can be adjusted very easily. The system also ensures same uniform volume from each & every cylinder. The mono block machine gives an accuracy of 0.25%. Although each & every cylinder discharges same volume of material. Hence maintaining accuracy. still individual settings of each & every cylinder can be done. The empty bottles are transferred to filling section by inbuilt conveyor through in feed worm & star wheel. After getting filled bottle pick the caps from cap chute thru cap shoe & then move to capping section where capping id done by rotary capping heads. After capping. Bottles are transferred to inbuilt conveyor by out feed star wheel & guide.

FILLING & CAPPING MACHINE – MONO BLOCK DESIGN COMPRISES OF :

The unit will be provided with a conveyor for conveying the empty bottles to the Filling Station. The body of the conveyor will be fabricated out of good quality laminated S.S. Sheet ASTM - 304, suitable for continuous heavy duty operation. The unit will be provided with imported S.S. Slat Chain and will be operated by German Speed variable Drive unit. The guides for the conveyor will be made from S.S. Flats. The conveyor guides are covered with a sleeve made of special polymeric material to prevent direct contact between bottles & metallic guides.

The top of the body is provided with S.S. Tray 75 mm * 38 mm covering all sides of the machine to collect water after washing and drain at back of the machine. The unit will be driven by 2.0 H.P. motor suitable for operation on AC/380V/3P/50C supply which drives the gear box of make “Elecon / Radicon” by the belt and pulleys. The unit will be provided with 3 S.S. doors and centralized lubrication system for all the moving parts inside the body.

• Centralized vacuum adjustment – Each & every cylinder can be adjusted for required volume with single setting which is very fast & precise. No downtime & accurate filling.
• No bottle- No fill ensures no wastage of product.
• No bottle –No cap ensures that no cap gets wasted.
• Machine will stop if less cap in chute.
• If cap chute is filled, cap feeder stop system of cap feeding to avoid cap getting damaged.
• Electronic level controller to control level of product in the tank
• Complete safety hood for better look & safety.
• Drip tray under the conveyor & all sides to collect the product in case of any breakage.
• Adjustable height of the machine to accommodate different height of bottling lines.
• Centralized lubrication ensures easy & smooth maintenance.

The homogenizers are useful for manufacturing suspensions, emulsions and homogeneous solutions. The equipment cons­ist of stator and rotor assembly made out of stainless steel. The stator is supported on the motor by means of stainless steel supporting rods and the-rotor moves inside the stator. The stator is provided with slots and the material passes through these slots several times and thus size reduction and homogenization is obtained. The unit is fixed on the self-supported stand having castor wheels. The up and down movement is obtained by means of telescopic arrangement.

HIGH SHEAR PRODUCTION MODEL

High Shear Mixers is capable of handling batches from 50ml to 50,000 Ltrs. Normally a mechanical seal above the shaft and flanges is provided to allow the mixer to be anchored to the top of an enclosed vessel. Suitable for either atmospheric or vacuum / pressure mixing, these mixers are designed for applications that require an extra measure of protection against contamination. Sanitary design models are also available. Various design of Head is available for High Shear Mixer but these can be broadly classified as Single Stage Design & Multi Stage Design :

SINGLE STAGE DESIGN:

The Single stage rotor/stator mixer is used for the production of Emulsions and Suspensions requiring a coarse to medium particle size with a narrow distribution. A single set of four blades rotates in the stationary stator. As the rotating blades pass each opening in the stator, they mechanically shear the particles and droplets, and expel the material at high velocity, creating intense hydraulic shear. With the rotor turning at 3000 to 4000 feet per minute(fpm), the generator applies intense mechanical and hydraulic shear. These mixers are available with variety of interchangeable stators to fine tune such functions as particle reduction, de agglomeration and emulsification. A vide range of options is available on the motors, base, material of construction . These mixers are easy for cleaning.

Accurately machined, vertical, rectangular openings provide a maximum surface shearing area. Small to medium sized solids are rapidly reduced with this head. Excellent circulation and high shear capabilities indicate its use for emulsions and other medium viscosity formulations.

Best applied for general purpose mixing or for particle size reduction. The round openings in this head provide the best circulation of all stators. This head is used for maximum circulation in fluids of higher viscosity.

A fine screen combined with an outer retaining head with larger openings provides for the highest possible shearing action. Difficult emulsification requirements or the suspension of fine powders are best carried out using this stator head combination

MULTI STAGE DESIGN:

Multi stage rotor/stator generators include two, three or four rows of rotating blades that nest inside a matching stator. The mix material enters the centre of the generator through an inlet connection and is accelerated outwards by centrifugal force. During each transit through the rotor/stator generator, the material is subject to a quick succession on increasingly intense shearing events until it finally exits the generator and is piped either to a downstream or re-circulated. By applying a series of shearing events with every pass through the generator, the multi stage mixer accelerates the mixing process dramatically.

QUAD SLOT:

The Quad slot mixer is a high shear, four stage dispersing mixer for the production of micro- emulsions and very fine suspensions. Four rows of the rotor/stator combination in a series produce a small particle or droplet size , with a very narrow distribution.

OPERATION

The unfiltered liquid is fed into the filter under positive pressure, where liquid travels in downwards direction and finds its way through opening on sides of the Filter Plates. As the liquid pressure increases, the Filter media holds the foreign particles and allows only clear filtrate to pass through the central channel formed by interlocking pressure cups to the outlet. Filtration is continued until the cake holding capacity of the unit is reached or until the filtrate rate becomes too slow owing to cake resistance. The Cartridge assembly consists of plates, perforated screens, spacers and fitter media. Interlocking spacers internally form single pipeline. The unfiltered liquid is centrally fed under pressure from bottom inlet. The liquids spreads out equally on each plate fitted with filter media. Solids remain on filter media and clear. filtrate flows through precisely made holes on sides of plates and collects in the shell, which then comes out through the outlet. In this process, solids are evenly distributed on each plate. The cake is then cleaned from the filter material and used again for filtration process.

FEATURES

• Single pass filtration with no solid bypass
• Full batch recovery, no separate scavenging system needed.
• Proper sealing which allows the filtration of volatile, toxic and inflammable products.
• Plate pack arrangement ensures
• Any type of filtering media singularly or in combination, can be used to achieve required micron efficiency. Easy removal and cleaning of the Cartridge Assembly.
• Closed System ensures
• Filtration of toxic, hazardous, explosive materials. Efficiently cleaned and sterilized.
• Central feeding ensures no solid inside the vessel, complete recovery of liquids.
• Cake solids can be maximum dried with N2 Complete cake retains over the plate.
• Uniform filter-aid bed can be formed.
• Reduces the cost of expensive solvents.

The values of "Flow-Rates" mentioned in technical specifications have been estimated for the following operating parameters:

Fluid : Water
Insoluble : Carbon
Filter media : Non-woven polypropylene cloth of 418 grade.
Carbon loading : 5 Kg/m2 filtration area.

In sugar syrup manufacturing plant, Centrifugal pumps are used for transferring Pre-mix or final mix to down stream stage. Mainly these pumps have extensive application for Syrup transfer, CIP water spray, Purified Water looping etc. Basic requirement of sanitary design is to have closed adherence to Hygienic demand of application. These all pumps meet the demand and uncompromising requirement in hygienic to ensure gentle product treatment. The motor pump is compactly designed by extending the SS shaft with complete alignment to facilitate draining, any leakage through packing arranged for minimal friction and perfect sealing. Normally dry mechanical seal is provided to avoid any leakage from pump shaft. These pumps are available from 0.5 HP to 10 HP model.

SALIENT FEATURES:

1. All contact parts in SS 316/304
2. Impeller is of casing SS
3. Mechanical seal is of Carbon, spring loaded, TC face
4. Inlet & outlet available with different connections confirming to SMS, DIN, IDF & TC as per requirement.
5. Low power consumption and low noise level
6. Motor can be assembled & disassembled easily.

Note : Detailed specification i.e. Flow rate, Discharge head, Impeller dia. etc. can be provided on demand.