Packaging machines: "We develop and build customized machines"

The right packaging concept for high-quality medical devices plays a key role. Having the right machine that produces this packaging is equally important. But what are the characteristics of a great packaging machine and what are the testing procedures? COMPAMED-tradefair.com asked Claus Weinert, who works with these types of machines on a daily basis.

Mr. Weinert, what types of packaging machines does your company offer medical technology clients?

Claus Weinert: We offer a wide range of blister packaging machines. Our packaging machinery forms, fills, and seals packaging. We also furnish feeding and handling systems like our own Delta Robots and downstream solutions, such as cartoner machines for blister packaging. Our diversified product portfolio covers the entire production process, from film to pallet.

Do you build solutions for your clients or do you deliver machines to customers?

Weinert: We produce packaging machines that are built and tested at our facilities and approved by our clients. We subsequently deliver the machines to the customers, where the packaging is manufactured.

Can you customize the packaging machines?

Weinert: We always develop and build customized machines that are tailored to fit our client’s needs. This means customers approach us with packaging specifications and we start by creating the packaging design. After the packaging design comes the development of the machine and the production line. We use modular systems, though the stations are typically custom-made to accommodate the packaging format.

What are the sterile medical device packaging standards you must comply with?

Weinert: There are specific requirements as it pertains to dust formation during the cutting process for example. Added to this are exacting demands on air sterility, which means you want to avoid air turbulence in the room and limit air supply as much as possible. This is achieved through reduced compressed air consumption. You have to remember that it costs money to decontaminate air per cubic meter. Customers want to save money in this area and we are the ideal partner at their side to make it happen.

How do you test and assess whether the machines meet the stringent required specifications?

Weinert: As an important unique selling point, KOCH typically performs an IQ /OQ validation (Installation Qualification / Operation Qualification). Unlike other manufacturers, this is already done at our facility by a team of specialists. This shifts the validation process to us and reduces installation time at the customer's production site. This is followed by a Factory Acceptance Test (FAT). The test evaluates the technical characteristics of the packaging. The machines are running and we check and verify that everything is operating in accordance with the individual steps noted in the customer's design specifications. Once this has been achieved, the machine is delivered to the customer. There is yet another test, the so-called "Site Acceptance Test" (SAT), where the customer runs the production line in the cleanroom to determine the functionality of the equipment at the site before its installation.

Is it easy for customers to switch between different packaging formats?

Weinert: Yes, that’s very easy to do and one of the major advantages of our packaging machines. Compared to other machines, our tools are more compact and light-weight, making it easier to quickly switch between different types of packaging formats. A fast and easy transition is our customer guarantee. Nobody wants to stop the production process for any amount of time, which is why a quick tool and format changeover is very important. We are especially proud of our foil width adjustment feature. Thanks to optimized settings, the foil width can be quickly adjusted. This ensures that our client saves time and reduces material costs. The latter is a crucial aspect for manufacturers. Oftentimes, there is no gap between the individual blister packs with our machines. This means optimized material utilization and cost reduction.

Do you offer special training sessions for your clients’ employees?

Weinert: We instruct employees during the FAT and then again during the SAT procedures. Associates receive a job orientation and learn how to operate the machinery at our site. The process is based on the iPhone user interface, making it very intuitive and easy. In fact, it’s so easy that trade fair visitors with no specialist knowledge were able to operate the machine and were pleasantly surprised to learn how easy it is. Added to this are our special service packages provided by our service staff: Our clients get a custom solution that ranges from basic training to specialized training packages.