DESIGN QUALIFICATION CARTONING MACHINE HI CART (BLISTER PACKING)
TABLE OF CONTENT
- Objective
- Scope
- Responsibility (Client and manufacturer)
- Machine description
- Technical specifications and make of sub-components/ bought out items.
- Details of Utilities
- Identification of components for calibration
- Material of construction of all components
- Safety features and alarms
- FAT procedure
- Change control procedure
- Qualification Document report approval
- Appendix
- OBJECTIVE:
- To design, engineer, and supply the Cartoning Machine HI CART (Blister Packing) as per the URS and to ensure that it complies with the Scope of Supply.
- To prove that each operation proceeds as per the design specification and the tolerances prescribed there in the document are the same at utmost transparency. Validation procedure is set for complete satisfaction of the customer & building confidence of the user in the machine.
- The scope of this qualification document is limited to the Design Qualification of Cartoning Machine HI CART (Blister Packing). This qualification document is part of a validation activity for the Cartoning Machine HI CART (Blister Packing).
- SCOPE:
- RESPONSIBILITIES
- CLIENT
- To check and approve the design qualification.
- MANUFACTURER
- To design, engineer and provide the complete technical details of the equipment pertaining to its design qualification viz.
- Machine overview,
- General arrangement drawing.
- Specifications of the sub-components/ bought out items, and their make, model & quantity, and backup records/ brochures.
- Details of Utilities,
- Identification of components for calibration
- Material of construction of all components
- Brief process description
- Safety features and alarms
- To facilitate the client for the Factory acceptance test of the machine at their works/ site.
- To confirm the safe delivery of the equipment to the user site.
- To ensure that no un-authorized and / or unrecorded design modifications shall take place. If at any point in time, any change is desired in the mutually agreed design, Change control procedure shall be followed and documented.
- To ensure the proper installation and commissioning of the equipment.
- To design, engineer and provide the complete technical details of the equipment pertaining to its design qualification viz.
- CLIENT
- MACHINE DESCRIPTION
- Purpose of Machine
- The purpose of the cartoning machine is to carton pack, unit products automatically into cardboard cartons.
- The machine performs following functions:
- Storing of pre-broken cartons in flat form in the carton magazine.
- Picking up the cartons from carton magazine.
- Opening / erecting the carton.
- Closing one side.
- Loading Leaflet.
- Loading product
- Closing other side.
- The machine consists of following main stations:
- Carton loading magazine.
- Carton pick up.
- Carton chain.
- Leaflet chain.
- Product chain.
- Product transfer mechanism.
- Carton Loading magazine
- This consists of adjustable guides in which different sizes of pre-broken cartons can be loaded. The guide adjustment is to be done manually, with the help of handles.
- Carton Pick up
- This arrangement picks up the carton from loading magazine and transfers it on the carton chain. Cartons are picked up with help of vacuum. Carton is not picked up if product or leaflet is missed out. This consists rotary drum pick up sucker arm, vacuum pump and vacuum valve.
- Carton Chain
- Carton chain holds and carries the carton while it gets opened, filled and closed. This is continuous motion chain. The carton opening and closing linkages operate in synchronisation with chain movement. The chain is in two sections, one fixed and other adjustable. This adjustment takes care of different carton widths.
- The chain carries in 3 versions, two chain, three chain and four chain. These 3 types are based on the 3 ranges of carton it can handle once the machine is built for a carton type (i.e. 2 chain or 3 chain or 4 chain) it can handle that range of cartons only. The machine can not be converted to other type of chain configuration. The subject machine is 3 chain machine.
- Product chain
- Products to be packed are carried on this continuously running chain and they are loaded into carton at the pusher station.
- The chain has pocket angles (cell angles) mounted on it. The product is carried between these angles. The distance between the cell angles is adjustable to handle various widths of product.
- All automatic product transfer mechanisms are mounted along this chain.
- The product chain also is made in two sections, one fixed and the other adjustable.
- Carton discharge
- After the carton is closed, the same is carried between two belts and discharged. This can be collected in a bin or a conveyor.
- Empty carton rejection system –
- This system is provided to detect and reject the empty cartons from the line. A sensor senses the product presence in the carton. If the product is found missing in any carton, that particular carton will be ejected with the help of pneumatic cylinder and prevented from going into production line. This ejected carton is collected in separate bin.
- Embossing station
- This station is used to give batch code embossing provision on the carton. The metallic stereos are fixed on the stereo roller and carton flap is passed through the stereo roller and pressure roller to get the impressions of stereos on the carton flap.
- Leaflet folding and transfer
- This attachment is provided to fold a flat leaflet and insert it into the carton. This station is provided after closing the bottom flaps and before loading the product into the cartons. There are folding plates and turning plates in the leaflet folding machine with which number of folds can be done as per specifications of customer and agreed by vandor. After folding, the leaflets are carried by belts and inserted into the cartons. The synchronisation of folding unit to cartoning machine is done.
- PLC Description
- This is operator control panel for operating various systems like mode selector key (inch / run), vacuum pumps and monitoring and setting the various parameters.
- PLC DETAILS:
- Model – FX on 40MT-DSS, 24 inputs & 16 outputs, Mitsubishi, Japan ,All inputs are 24 VDC supply.
- MMI DETAILS:Model – E300
- Make- Beijers, Sweden. (Supplied by Mitsubishi)
- Input supply – 24 VDC +/- 10%
- Display – 4 line display
Operator panel developed to satisfy the demand made for operator and machine communication. The various devices can be monitor and PLC data changed through the screens in E100. It is equipped with dynamic indication alarm .
- TECHNICAL SPECIFICATIONS:
Description | Specification |
Model | HI-CART |
Type | Continuous motion automatic cartoning machine |
Dimension | 5108mmx1657mmx2100mm
(LxBxW) |
Carton size range | |
Width | 20mm to 75mm |
Height | 14mm to 65mm |
Length | 65 mm to 180 mm |
Leaflet size range (unfolded) | |
Width | 110 to 170 |
Length | 80 to 240 |
Leaflet GSM | 45 to 60 |
Output | 25 to 220 Cartons / min |
Carton closure | Reverse tuck in |
Carton GSM | 280 to 400 |
Overprinting | Overprinting /embossing is possible only on main flap rear |
Embossing | Maximum number of letters possible in one line is 15 (size 1.59) Lines possible is 4. |
- TECHNICAL SPECIFICATIONS OF COMPONENTS & SUB- COMPONENTS USED / BOUGHT OUTS
Description | Specification |
1. Cell angle | |
Material | Aluminium |
Location | Conveyor Chain |
2. Straight knurling roller | |
Qty. | 04 Nos. |
Location | Leaflet folding |
3. Pressure roller | |
Qty. | 04 Nos. |
Location | Leaflet folding |
4. Ink carrying roller | |
Material | Neoprene rubber |
Location
|
Overprinting & Embossing Station |
- Part B = Sub-Components / bought out items
Description | Specification |
1. Main geared motor | |
Make | Bonfliglioli |
Type | 3 Phase Induction Motor |
Model | BN90LA4 |
Voltage | 415V |
Power | 1.5 kw |
Location | Structure and drive |
2. Gear box | |
Make | Bonfliglioli |
Type | MAS251P |
Ratio | 10:53 |
Location | Structure and drive |
3. Product chain | |
Size | 1/2 ” |
Location | Structure and drive |
4. Carton chain | |
Size | 1” |
Location | Structure and drive |
5. Machine Mount | |
Make | Av Mount |
Type | M12 |
Description | Specification |
Location | Structure and Drive |
6. Vacuum pump | |
Make | Indovac |
Sr. No. | 532074 |
Description | Specification |
Rating | 1 HP |
RPM | 1440 rpm |
Vaccum | 26” Hg |
Capacity | 300 LPM |
Location | Carton pickup & Transfer & Pre breaking |
7. Vacuum Pump Motor | |
Make | Siemens |
Sr. No. | 0505045015 |
Motor Rating | 0.75 KW |
Type | 3 Phase Induction |
Voltage | 380-415 V AC |
RPM | 1415 rpm |
Location | Carton Pickup & Transfer & Pre breaking |
8. Vacuum pump | |
Make | Indovac |
Sr. No. | 4121950 |
Rating | 2 HP |
RPM | 1440 rpm |
Description | Specification |
Vaccum | 26” Hg |
Capacity | 500 LPM |
Location | Carton pickup & Transfer & Pre breaking |
9. Vacuum pump motor | |
Motor make | Siemens |
Sr. No. | 0410029290 |
Motor Rating | 1 .5 KW |
Type | 3 Phase Induction |
Description | Specification |
Voltage | 415 V AC |
RPM | 1415 rpm |
Location | Carton Pickup & Transfer & Prebreaking |
10. Sucker for Carton Pick Up | |
Qty | 06 Nos. |
Location | Carton Pickup & Transfer |
11. Sucker for Carton Prebreaking | |
Qty. | 02 Nos. |
Location | Prebreaking |
12. Solenoid Valve | |
Make | Legris |
Capacity | 1.59-9 bar |
Description | Specification |
Location | Product Pushing |
13. Chain Plate (Small without thread) | |
Make | Ambika |
Material | Derlin Gray Colour |
Location | Product Pushing |
14. Vacuum Pump | |
Make | Indovac |
Sr. No. | 512027 |
RPM | 1440 rpm |
Rating | 1 HP |
Description | Specification |
Capacity | 300 LPM |
Vacuum | 26” Hg. |
Location | Leaflet Folding |
15. Vacuum Pump Motor | |
Motor make | Bharat Bijlee |
Sr. No. | N2434687 |
Motor Rating | 1 HP |
Type | 3 Phase Sq. Cage Induction Motor |
Voltage | 373- 456V AC |
RPM | 1405 rpm |
Location | Leaflet Folding |
16. Belt For Leaflet Transfer | |
Make | Habasit |
Size | 12.5 x 0.645 mm |
Location | Leaflet Folding |
17. chain for leaflet clamp | |
Size | 1/ 2” |
Location | Leaflet Folding |
18. Ink | |
Make | Aditya system |
Specification | A-50 |
Location | Overprinting & embossing unit. |
19. Cylinder for Ejection | |
Make | Festo |
Model | 91265D23 |
P max | 8 bar |
Description | Specification |
Range | 16 x 50 |
Location | Empty carton rejection |
20. Solenoid valve | |
Description | Specification |
Make | Legris |
Pressure | 1.59-9 bar |
Location | Empty carton Rejection |
21. Discharge Belt | |
Make | Habasit |
size | 30×110 |
Location | Empty Carton Rejection |
22. A.C Drive | |
Make | Mitsubishi E500 |
Model | FR-E540-1.5 k |
Location | Controls |
23. Single phase preventor | |
Make | Minilec |
Sr. No. | 4U3717 |
Model | ALV-DL |
Rating | 380-440 VAC |
Location | Controls |
24. Power supply | |
Make | NHP |
Sr. No. | 100105 |
Voltage | O/P 24 V – 10A |
25. P.L.C. | |
Location | Controls |
Make | Mitsubishi |
Type | FX ON –40 MT –DSS |
Location | Controls |
Description | Specification |
26. M.M.I. | |
Make | Bejers-Sweeden |
Type | E 300 |
Location | Controls |
27. Encoder | |
Make | Raj Deep |
Type | BBTT |
28. Pressure Gauge | |
Make | Legris |
Dial Size | 1.5” |
Range | 0-10 kg / cm2 |
Location | FRL unit / Pressure Regulator Unit |
Qty. | 2 Nos. |
29. Pressure Switch | |
Make | Orion |
Model | MEH07CB10 |
Sr. No. | A05010548 |
Location | Machine Base |
Qty. | 2 Nos. |
30. Vacuum Gauge | |
Type | AL01 |
Range | 0 to -760 mmhg |
Location | Vaccum Pumps |
Qty. | 3 Nos. |
Description | Specification |
31. Blister Check Sensor | |
Make | IFM |
Qty. | 02 Nos. |
Rating | 36 V / DC |
Sr. No. | 0G50430GEFPKG/US
0G50420GS-00KG/US |
Description | Specification |
32. Leaflet Check Sensor | |
Make | IFM |
Sr. No. | 0G50530GH-FPKG/US |
33. Carton Check Sensor | |
Make | IFM |
Sr. No. | 0G50530GH-FPKG/US |
34. Carton Level Sensor | |
Make | IFM |
Sr. No. | 0G50530GH-FPKG/US |
35. Check Sensor for empty Carton | |
Make | IFM |
Sr. No. | 0G50530GH-FPKG/US |
36. Blister Check Sensor for Empty Carton | |
Make | IFM |
Sr. No. | IDC3050BBPKG/2LED/US |
37. Arm Rotation Sensor/ Liver Check Sensor | |
Make | IFM |
Description | Specification |
Sr. No. | AP024-5000L |
38. Ganter Reading Knobs | |
Qty. | 20 Nos. |
Type | BBTT |
Make | Raj Deep |
Location | 04 (Mazzine) / 08 (Front Side Closing) / 08 (Rear Side Closing) |
39. Cooling Fan | |
Make | Rexnord |
Model | REC2203882 |
Location | Control Panel |
- Details of utilities
Description | Specifications |
6.1 Electrical | |
Phase | 3 Phase |
Voltage | 415V |
Frequency | 50 Hz |
6.2 Compressed Air | |
Flow pressure | 6 bar |
Quality | Oil, water and dust free |
Max. consumption | 1 cfm |
- IDENTIFICATION OF COMPONENT FOR CALIBRATION
In the Cartoning Machine HI CART (Blister Packing), following components need calibration. They shall be calibrated during/ before installation of the equipment at the site:
- Vacuum Gauge (Carton pickup, transfer & prebreaking)
- Vacuum Gauge
- (Carton pickup, transfer & prebreaking)
- Vacuum Gauge (Leaflet folding)
- Pressure Gauge (2 Nos.)
- MATERIAL OF CONSTRUCTION
Description | Specification | Meets
Spec. Yes/No |
Verification Source | Initials | Date |
Cladding | SS 304 | ||||
Carrier angle | S.S. 304 | ||||
Blister magazine | SS 304 Sheet | ||||
Control panel and operating panel | S.S 304 | ||||
Carton guides | S.S. Buffed | ||||
Flap closers | S.S. Buffed |
- SAFETY FEATURES
- All the electrical components, which are having high voltage, are covered with proper cover.
- All the electrical / electronics components are mounted in a fully enclosed cabinet. This provides proper safety from live parts.
- All moving parts are covered with proper guards with interlocks for some guards.
- All necessary guards are provided with safety switches interlocks. In case of removal of the guard, the machine will stop instantly.
- Two emergency switches are provided in the machine, one at operator panel and other at discharge end of the machine. Once it is pressed, machine will stop instantly.
- Overload interlock is provided at pusher station.In case of any jamming during pushing, this interlock will actuate and machine will stop instantly.
- All motors are connected through overload relays.In case of overload or jamming in the motor side or drive side, this relay will trip the motor and machine.
- Any of the electrical phase failure or phase disconnection, single phase disconnection, single phase preventor unit will trip the machine instantly.
- All electrical parts and full machine are earthed properly.
- Operator handling areas such as sensors, operator panel, switches etc. are having low voltage (i.e. 24 VDC).
- Prevention of oil contamination with product.
- All main drive element e.g. motor and gearbox are mounted on machine base which is well below product chain and carton chain.
- All the drive transmission parts such as chains and sprockets fall below the product and carton chain level.
- Since the lubrication is not forced, the oil travelling upward is technically not possible hence oil contaminating the carton/product is not possible.
Primary pack contact surfaces:
- Following are components which come in contact with product the primary pack :
- Blister magazine: SS 304 Sheet Polished surface
- Cell angle: Aluminium Buffed
- Chain plate: Delrin
- Pusher: Aluminium Anodised
- Following are components which come in contact with carton:
- Carton magazine: S. Bright Nickel plated
- Carton guides: S. Buffed
- Flap closers: S. Buffed
- Carton chain: S. Bright nickel-plated
- Discharge conveyor belt: Rubber PU coated
- LIST OF ALARMS/ INTERLOCK:
Sr. No. | Fault | Alarm |
1. | Air Pressure Minimum | If the air pressure drops below the minimum set level(5 bar), then this alarm will trip the machine and will display “LOW AIR PRESSURE”. |
2. | Empty Carton Magazine | If Carton level in the magazine is reduced, the machine will stop and will display message “LOW CARTON LEVEL ” |
3. | Machine Guards open | If machine guards are opened during running OR are not closed properly machine will stop giving message “GUARD OPEN” |
4. | Emergency OFF is pressed | When emergency stop is pressed machine will stop instantly indicating “EMERGENCY OFF” message. |
5. | Hand wheel out | If hand wheel is out machine will not start giving “HANDWHEEL OUT” message. |
6. | No product No Carton | If there is no product in any of the pocket in product chain, the same is sensed and the machine does not pick up the carton corresponding to that pocket. |
7. | No Leaflet, No Carton | If a leaflet is not picked up then corresponding carton is also not picked up. |
8. | No Product, No leaflet | No leaflet is picked up for a pocket if product is not present in that pocket. |
9. | Jamming during pushing. | Overload interlock is provided at pusher station. Incase of any jamming during pushing, this interlock will actuate and machine will stop instantly.
|
10. | Vacuum Pump | If vacuum pump is not working , the mahine will not start. |
- FAT PROCEDURE
Factory Acceptance Test Procedure shall be as follows:
After the completion of erection work of the machine, client shall be requested to perform the factory acceptance test (FAT).
Client shall perform the FAT at the manufacturer site and record all the data in the prescribed FAT document as per the details given below:
- Functioning of Machine operating panel with MMI
- Interlocks and safety features provided.
- Details of major components fitted on the machine
- Carry out product run and fill test criteria with product.
- Check deficiency and corrective action taken report.
- Fill up chart of pre-requisites of installation.
- CHANGE CONTROL PROCEDURE:
- Change in the agreed design shall be addressed through the well-defined Change control procedure.
- DESIGN QUALIFICATION REPORT
- APPENDIX
- LIST OF ABBREVIATIONS
FAT | Factory Acceptance Test |
AC | Alternate Current. |
MS | Mild steel |
PLC | Programmable Logic Control |
SS | Stainless Steel |
MNP | Matt Nickel Plated |
K.W. | Kilo Watt |
DQ | Design Qualification |
Hz | Hertz. |
Kg | Kilogram. |
MMI | Man Machine Interface |
C.I. | Cast Iron |
No. | Number |
UHMWPE | Ultra high molecular weight polyethylene |