Intertech Technologies Pvt. Ltd.

The Cream Manufacturing Plants are ideal tools for the pharmaceutical industry for the production of Sterile & Tropical Creams. Majority of Creams are emulsion based & this emulsion is prepared using hot mix technology. Both Water & Oil/Wax are heated separated in Pre-Mix tanks & finally transferred into Main Batch Mixers where High speed Emulsifier creates laminar thinning of material & forms emulsion. Broadly end product can be a blend of various ingredients including drugs in liquid form or dispersed phase of ingredients where drugs are added into powder form. Therefore designing of entire Cream 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. Cream manufacturing systems comprises of equipment for automated Water & Wax transfer , double jacketed and non jacketed vessels for Heating & Cooling application, compounding / ingredient mixing and storage with product distribution piping. The range covers capacities from 50 Kg to 5000 Kg with various options in top and bottom entry agitators & homogenizers for mixing and homogenizing of ingredients . We offer a range of precision engineered Sterile Cream manufacturing plant which is completely compatible to CIP (Clean In Place) & SIP (Sterilization In Place). Advanced processing technology offers consistently high product quality, shorter batch cycles, minimal operating costs, low space requirements and simple operations

Cream Manufacturing Plant consist the following equipments and accessories:

• Water Phase Vessel
• Wax Phase Vessel
• Batch Manufacturing Vessel
• High speed homogenizer & emulsifier
• Transfer pumps
• Storage Vessel
• Control Panel
• Product Piping
• Working Platform

BASIC DESIGN FEATURES & OPERATION:

• Entire plant consist of a closed circuit manufacturing facility from feeding of Wax / Water Phase / Ingredients up to loading into Filling Machine.
• The Water is metered & loaded using Flow meter for precise feeding.
• Both water & wax phase vessels are jacketed for heating & equipped with suitable stirrer & disperser. The Main Batch Vessel is fitted with Slow speed Main agitator for blending & distribution effect & also supported by additional high speed homogenizers. Heating & Cooling provision thru jacket is there. In typical process demand, Online Homogenizer can also be provided for fine texture of end product. In main Batch Mixer, Mixing & other process is achieved using vacuum to avoid air entrapment. The Cream prepared is transferred to Storage Vessel by transfer pump.
• Various type of Mixer are fabricated as per product used viz. Double Contra Rotary Mixer, Fixed Baffle Mixer etc.

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.

GENERAL DETAILS

Aluminum Tube filling & Crimping machine in single head version is capable of filling & crimping aluminum tubes in fully automate manner. Essential automatic configurations, which include a tube storage cassette box, tube loading; orientation, positive fill and closure stations are included in the basic supply. Minimal maintenance interventions, and accommodating in lesser space with a thorough output up to 4,500 tubes per hour, are some of the main features. This machine complies with but also exceeds GMP standard

BASIC MACHINE is supplied complete with the following:

• Nine Stn. Mechanically driven machine, built on Angles & Mounting plates in M.S. duly powder coated. All brackets in M.S, OHNS duly ENP plated. Turret is made of LM-04 powder coated (aluminium casting) All cams and levers in C.I casting. Contact parts with the Creams are of S.S.316L material. General parts are ENP, powder coated or blackodized to avoid rust. S.S covers guard all parts below main functioning area.
• Cassette type auto feeding of Tubes into tube socket
• Photo-electric tube print registration unit, which ensure correct positioning of the tube ‘I’ mark prior to crimping. Consist of stepper motor and contrast sensor Tube holder (9 pcs. & 2 as spares) for any one-tube size.

• Suitable capacity stainless steel single wall hopper of SS 316
• S.S. - 316L Pump head for filling, which consists of valve. Seals are provided on the sides of the valve to avoid leakage of Cream. A horizontal piston-dosing pump, Teflon piston placed in S.S. cylinder, carries out the dosing with independent volume fill track adjustment. There will be filling syringes which are actuated by single cam. Block is provided each under hopper which delivers material to syringe.
• Combination of blow-off, cut-off or valve-type Filling nozzles, which eliminates product dripping / stringing, and maintains filling accuracy.
• Bottom-up filling. Rise and fall of the tube is controlled by a mechanical cam designed according to the filling product characteristics
• Tube crimping 1st & 2nd fold at separate station, Pneumatically
• Pneumatically operated batch-coding station
• Automatic discharge of tube. (Tail first)
• Covers below the machine table are in stainless steel S.S 304
• Electrical system consists of a trouble-free electrical panel, along with operating panel board.
• One set of Size parts for one filling product along with One set of tools kit

OPTIONALS

• Electrically heated thermostat jacketed hopper for hot fill (In lieu of single wall hopper)
• Agitator driven by a ½ HP, 20 RPM, 3 phase vertical geared motor. Agitator blades & contact parts in S.S.316L, along with mounting, switches & temperature indicators
• A.C. Drive regulates the speed of the machine. Load on any of the stations triggers the A.C. drive to stop the motor.
• Tube cleaning device for cleaning empty tube by vacuum suction, provided by a Vacuum pump with filters and vertically diving type cleaning nozzle.

SALIENT FEATURES

• No tube no fill arrangement
• Overload protection of piston syringe
• Pneumatic cut off in nozzle to avoid product dripping
• Hopper & block mounting on quick release design for faster cleaning
• Surface hardening of piston & cylinder for higher life
• Very low weight variation (+/- 1%)

GENERAL DETAILS

Empty Containers are fed manually or automatically through turn table. The empty containers are carried by the belt or slat conveyor up to the filling station. At the filling station containers are selected and pushed forward though a chute on a platform below the filling nozzles and the filling operation takes place. After filling subsequent batches of containers are filled and further pushed forward on the collection platform .

BASIC MACHINE is supplied complete with the following:

• Suitable capacity stainless steel single wall hopper of SS 316
• S.S. - 316L Pump head for filling, which consists of valve. Seals are provided on the sides of the valve to avoid leakage of Cream. A horizontal piston-dosing pump, Teflon piston placed in S.S. cylinder, carries out the dosing with independent volume fill track adjustment. There will be filling syringes which are actuated by single cam. Block is provided each under hopper which delivers material to syringe.
• Combination of blow-off, cut-off or valve-type Filling nozzles, which eliminates product dripping / stringing, and maintains filling accuracy.
• Nozzle is mounted on header which is actuated by Cam or by Pneumatic cylinder for diving type filling arrangement.
• Covers below the machine table are in stainless steel S.S 304
• Electrical system consists of a trouble-free electrical panel, along with operating panel board.
• One set of Size parts for one filling product along with One set of tools kit
• Infeed conveyor of SS Slat is provided, after un-scrambler, before filling head. Out feed conveyor is provided for discharge of conveyor before scrambler (turn table)
• SS slat conveyor will be provided with guide bar to move jars.

OPTIONALS

• Adjustable type Turntable for loading & unloading containers. Unit is supplied along with an automatic Infeed conveyor system, fitted with an A.C. Drive to regulate the feeding speed.
• Variable frequency drive for Slat conveyor
• Electrically heated thermostat 35 liters stainless steel jacketed hopper for hot fill (In lieu of single wall hopper)
• Agitator driven by a ½ HP, 20 RPM, 3 phase vertical geared motor. Agitator blades & contact parts in S.S.316L, along with mounting, switches & temperature indicators
• A.C. Drive regulates the speed of the machine. Load on any of the stations triggers the A.C. drive to stop the motor.

SALIENT FEATURES

• No container no fill arrangement
• Overload protection of piston syringe
• Pneumatic cut off in nozzle to avoid product dripping
• Hopper & block mounting on quick release design for faster cleaning
• Surface hardening of piston & cylinder for higher life
• Very low weight variation (+/- 1%)

• Convinced optimized design
• Long life
• Flawless finish

GENERAL DETAILS  

Laminated plastic tube filling & sealing machine in single head version is capable of  filling & sealing of Lamy / Plastic tubes  in fully automate manner. Essential automatic configurations, which include a tube storage cassette box, tube loading; orientation, positive fill and closure stations are included in the basic supply. Minimal maintenance interventions, and accommodating in lesser space with a thorough output up to 4,500 tubes per hour, are some of the main features.

BASIC MACHINE is supplied complete with the following:

• Mechanically driven machine, built on Angles & Mounting plates in M.S. duly powder coated & cladded.  All brackets in M.S, OHNS duly ENP plated.  Turret is made of LM-04 powder coated (aluminum casting) All cams and levers in C.I casting.  Contact parts with the Creams are of S.S.316 material. General parts & covers are ENP - weed blasted, powder coated or blackodized to avoid rust. S.S Covers guard all parts below main functioning area.  The above/ below portions of the machine general parts are ENP or Anodized, therefore this machine is durable, rustproof and easy for cleaning. 
•  Tube holder set, for any One-tube size. Holders are designed as per sample, tube size, material and cap design.
• Cassette type feed device for automatically feeding empty tubes into the in-feed device, consisting of cassette -magazine fitted on the machine.  Empty tubes, comes down from the cassette on a slider plate. The tilter holds the tube by vacuum, loads it & lodge it into the tube holders with a centering / pressing cone.
• Photo-electric tube print registration unit, which ensure correct positioning of the tube ‘I’ mark prior to Crimping / Sealing
• The No tube - No fill device.  Prevents the dosing action if tube is not present
• Cream dosing Pump head.  A piston-dosing pump, consisting of Teflon piston placed in S.S. cylinder carries out the dosing.  One set of piston and cylinder can fill the following range. 3 - 12 cc.  / 12 - 30 cc.  / 30 – 100cc  (Depending on material characteristic). Filling volume adjustment is done using touch screen PLC by Servo driven motor mechanism.
• Filling nozzle consisting of a Positive cut off system, helps eliminates product dripping / stringing, and maintains filling accuracy.  (All contact parts are in food-graded material)
• Hot Air blowing station for melting Plastic-Laminated tubes.  Hot Air is blown through a hot-air tool, on to the sealing area of the tube.  When the tube is lifted for heating, a cooling block (Chilled water is circulated through it) to have a dent free seal. 

OPTIONALS

• Electrically heated thermostat  jacketed hopper for hot fill (In lieu of single wall hopper)
• Agitator driven by a ½ HP, 20 RPM, 3 phase vertical geared motor. Agitator blades & contact parts in S.S.316L, along with mounting, switches & temperature indicators
• A.C.  Drive regulates the speed of the machine.  Load on any of the stations triggers the A.C. drive to stop the motor.
• Curve / Wave & Half moon type sealing pattern are also available
• Low viscosity type product filling thru volumetric syringe is also availabl

SALIENT FEATURES

• No tube no fill arrangement
• Overload protection of piston syringe
• Pneumatic cut off in nozzle to avoid product dripping
• Hopper & block mounting on quick release design for faster cleaning
• Surface hardening of piston & cylinder for higher life
• Very low weight variation (+/- 1%) 

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.

• As the lobes come out of mesh, they create expanding volume on the inlet side of the pump, Liquid flows into the cavity and is trapped by the lobes as they rotate.
• Liquid travels around the interior of the casing in the pockets between the lobes and the casing -- it does not pass between the lobes.
• Finally, the meshing of the lobes forces liquid through the outlet port under pressure.

• Externals (head, casing) - Typically 316 or 316L stainless steel head and casing
• Externals (gearbox) - Cast iron, stainless steel
• Internals (rotors, shaft) - Typically 316 or 316L stainless steel, non-galling stainless steel
• Shaft Seal - O-rings, component single or double mechanical seals, industry-standard cartridge mechanical seals

• Non Contact highly polished Lobes
• Choice of Lobe profiles, Bi-Lobes / Tri-Lobes / Gears
• Heavy duty long lasting mechanical seals
• Universal mounting horizontal or vertical suction
• Inlet / Outlet with BSP / Tri-Clover / SMS and Flanged connection
• Jacketed casings for solidifying liquids
• Reversible rotation

• As the piston moves back & forth, during reverse motion, suction is created into inlet line & liquid is forced out during forward stroke.
• Stroke movement is controlled using cam mechanism for variable discharge demand.
• Necessary Non return valves are fixed in suction & discharge line.

• Precise metering devices
• Metering accuracy is almost independent of back pressure
• Flow rate is linear to stroke length variations
• Multiple head plunger pumps with common drive for mixing two or more liquids in a desired ratio. The ratio can be easily set
• Jacketed Liquid heads can be heated by hot water/steam. Ability to transfer & dose products which are highly viscous at room temperature.
• External arrangement for flushing the gland packing to increase its life is also possible