Pharma: continuous aseptic packaging

A steady stream of demand for complete lines has driven Omas Tecnosistemi to create a range of machines for sterile products, from depyrogenation bottle-washing tunnels, completing the line with an intermittent or continuous filling monoblock, stoppering and ring-sealing of liquid or powder products, according to need.

The advantage of a complete line. The continuous aseptic process guarantees significant advantages compared to production in batches, since the process is automatic and guarantees decontamination of microorganisms and endotoxin particles.  The system offered by Omas is made up of a GRW bottle-washing machine, designed and built according to GMP guidelines in order to offer maximum versatility and efficiency; the system uses both filtered water for the initial phases and purified water for the final steps, reducing wastage, while intermittent spraying further reduces the amount of water used to no more than 3 liters/minute. Non-penetrating nozzles guarantee elimination of broken bottles and the complete integrity of the glass. The range of the ampoules is from 1 to 500 m (tubing and hygienic connectors are electro-polished), guaranteeing a highly efficient bottle washing process.
The recipes can be selected via PLC and configured using a fast and intuitive touch screen. High speed changeover is guaranteed by the quick format parts disassembly system.

The entire system is managed by a servomotor, and the automatic unloading system at the end of line delivers the bottles directly to the hot air sterilization tunnel.
The depirogenation tunnel is automated, requiring no operator intervention and guarantees decontamination, making it fast, flexible and efficient. This step takes less than 30 minutes.
The sterilization tunnel consists in three chambers (pre-heating, sterilization and cooling), separated by gates, and the height is automatically adjusted by the PLC as part of the recipe for the bottle in the main chamber, where the operating temperature is 320 degrees Celsius, guaranteeing complete elimination of all bacteria. The HEPA filters are installed inside.
Each chamber of the tunnel is configured for conducting DOP testing and particle counts.

Projects for the future. Omas aims to implement this new department dedicated to building machinery for the pharmaceutical sector, also in light of the fact that, by the end of the year, the concern will unveil its new production site, with 4,000 m2 of surface area; in such a way, the 10,000 m2 facility will guarantee an increasingly wide-ranging and qualified offer.