Upgrades and accessories for filling systems

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1 Bosch Packaging Services Upgrades and accessories for filling systems Numerous upgrade and accessory kits are available for your filling systems. Please get in touch with us - together we will find solutions which best fit your requirements.

2 2 Bosch Packaging Services Rotary valve pump pump cylinder made from one piece The manufacturing process of the new pump cylinder distinguishes itself by the complete machining of this part from one piece. The manufacturing of the cylinder from one single material batch and consequently defined material quality of (316L) guaran - tees an absolutely homogenous material quality and traceability. Rotary valve pumps made of zirconia ceramics The rotary valve, piston and sleeve are made of zirconia ceramics. The pump cylinder is made of aluminium oxide ceramics. In comparison with aluminium oxide ceramics, zirconia ceramics distinguishes itself by a higher flexural and impact strength. The rotary valve pumps completely made of aluminium oxide ceramics are available as well.

3 3 Bosch Packaging Services Rotary valve pumps including material certificates The documentation and traceability of batches produced in the pharmaceutical industry are of key importance. Graduated prices for rotary valve pumps No matter if you need rotary valve pumps made of stainless steel, ceramic or CIP/SIP pumps, you will get significantly reduced prices when purchasing larger quantities. We will be happy to provide you with a quotation. Your benefits 3.1 certificate included No additional costs Replacement of individual pump parts Scale prices Replacement of repair pump with new pump Material certificates can be obtained for our product-contact parts. Going forward, our rotary valve pumps include the following documents at no extra cost: 3.1 certificate Leak test report Cleaning and safety instructions After inspection, individual pump parts such as piston, rotary valve or cylinder can be replaced with pumps manufactured from With the replacement, the material certificate is updated accordingly. In addition, our scale prices for orders of min. 7 pumps still apply. Standard stainless steel pumps sent to us for pump repair are checked after receipt. If the pump is repairable, you will receive an offer for the pump repair. The average repair time is about 8 to 12 weeks. You can choose between a pump repair and the purchase of a new stainless steel pump from our stock at the price of the pump repair. Your benefits immediately available new pump from stock pump at the price of a pump repair one year warranty for new pump If you decide in favour of a new pump, we will dispose of the defective pump free of charge.

4 4 Bosch Packaging Services Moistening cups for rotary valve pumps Moistening cups are mounted at the piston or between the cylinder and rotary valve of a rotary valve pump. They are very useful if the piston seizes in the cylinder due to the specification of the product, i.e. certain products slightly crystallize out and the piston no longer moves smoothly in the cylinder. Moistening cup with O-ring at piston Cylinder Piston The moistening cup with the O-ring serving as a seal is mounted at the bottom of the piston or between the cylinder and rotary valve. Depending on the requirements, it is filled with alcohol, WFI or distilled water. The piston or rotary valve is permanently moistened by the liquid in the moistening cup. This largely prevents the piston from getting stuck. Utility (alcohol, WFI, distilled water) Seal (O-ring) Moistening cup Upper dead centre Lower dead centre Moistening cup at the piston of a ceramic pump Moistening cup with O-ring Moistening cups for standard pumps Volume in ml Pump no. Machines Moistening cup incl. O-ring 0,3 1, ALK/ALF/FLS/MLD/FLM ALK/ALF/FLS/MLD ALK/ALF/FLS/MLD ALK/ALF/FLS/MLD MRF/FLM

5 5 Bosch Packaging Services Pump mounting device for rotary valve pumps The pump mounting device is an ideal mounting and dismounting aid for rotary valve pumps. This device was developed for the non-contact rotary valve pump mounting into the pump support of our filling machines. The pump consisting of a cylinder, piston and rotary valve is positioned in the pump mounting device in correct position so that the pump parts cannot be mixed up. Pump parts are prevented from getting loose during the mounting and dismounting of the pump. As a result, damage to the pump parts is avoided. By means of this device, rotary valve pumps can be mounted and dismounted quickly and safely with one hand. Set-up times are reduced. In the sterile room or isolator, pump mounting with gloves is difficult. With this device, it is possible to mount the pump with one hand only. The parts of the device which are in contact with the rotary valve pump are made of Tecapeek. During sterilization in the autoclave, the part are resistant to deformation even with high temperatures. All other parts are made of stainless steel (316L). Process safety during batch or size change is increased by this non-contact assembly. The pump mounting device is especially suitable for applications in isolators and barrier systems. Alternatively, a pump mounting device version is available which allows for the sterilization with the pump parts remaining in the device. By pulling the frame apart, the careful sterilization of all individual pump parts can be ensured.

6 6 Bosch Packaging Services Storage and sterilization tray for rotary valve pumps The sensitive rotary valve pumps of the filling machines have to be cleaned and sterilized regularly in accordance with the strict pharmaceutical regulations. To facilitate the cleaning and sterilization process, we offer special trays. The unit consists of a universal base frame made of stainless steel, material / (316L), and is stackable and portable. The base frame accommodates one large or three small trays. Carrying plates, which are available in two sizes, are inserted into this frame. These carrying plates, which are also made of (316L), can be used for all pump types and versions of the Pharma Liquid standard range of products. The carrying plates come with base plates and supports where the pump parts such as cylinders, pistons, rotary valves, sockets, union nuts and sealing elements are plugged. The supports of the base plates are designed in a way that the pump parts to be sterilized do not touch each other. So all pump parts can be cleaned and sterilized perfectly all over. Due to this orderly storage it is guaranteed that no pump part is missing.

7 7 Bosch Packaging Services Seal kit for CIP/SIP pumps A seal kit acc. to USP class VI is available for all CIP/SIP pump sizes. The seals, which are made of platinum-cured silicone, distinguish themselves in terms of excellent product compatibility. The pump seal kit consists of the flat seals for product feeding and rinse lines as well as the O-rings for sealing the rotary valve and piston. Considering replacing the seals of your CIP/SIP pumps in the near future? Seal kit for CIP/SIP pumps Overload clutch for rotary valve pumps Pump micro adjustment with overload clutch For a better protection of the rotary valve pumps the central overload clutch for the pump stroke was replaced with individual overload clutches at each pump micro adjustment unit. If a problem occurs at one pump, the overload clutch disengages and the machine stops immediately. This upgrade can be implemented on all AVRs and ALKs. Your benefit Significantly increased safety for each individual pump.

8 8 Bosch Packaging Services Laser welding of filling needles Laser welding of filling needles When manufacturing filling needles, Bosch relies on laser welding. With laser welding, the materials are connected with - out filler metals. There is nearly no secondary heat due to the short time span from melting to hardening of the metal. Material stress is reduced to a minimum by selective energy supply. Structural changes and distortion are thus largely avoided. Scale discounts for filling needles For your Bosch machines we recommend that you stock a sufficient number of filling needles to ensure the smooth operation of your filling and sealing machines. To facilitate stock control and procurement planning of these consumables for you, we have fundamentally revised our pricing structure on these vital parts. You will benefit from our attractive scale prices when you purchase filling needles in larger quantities, as illustrated in the discounts below: From 6 pieces: 25% bis 35% * From 12 pieces: 35% bis 45% * From 24 pieces: 40% bis 50% * Your benefits Genuine Bosch quality parts at competitive prices One-stop shop for technical know-how and servicing Excellent stock availability We would be happy to assist you in planning your long term needs. Please do not hesitate to contact us for more information. * depending on type of filling needle

9 9 Bosch Packaging Services Filling needles made of TECAPEEK TECAPEEK (Polyetheretherketone) filling needles are available for products which have to be filled metal ion free or which are sensitive to metals. This FDA-compliant material has a very good chemical stability. The needles are therefore insensitive to cleaning agents or corrosive products and even resistant against oxidizing agents such as acids. Due to their stiffness and strength the TECAPEEK needles can also be used for warm fill products. The filling accuracy and performance correspond to the traditional stainless steel needles. In comparison with stainless steel needles, they have a lower weight which facilitates the loading of autoclaves. Besides autoclaving, the TECAPEEK needles can be cleaned by gamma sterilization. Filling needles made of TECAPEEK are suitable for all Bosch filling systems. As a standard the following sizes are available: outer diameter 2.0 to 8.0 mm (<2.0 mm on request). Your benefits Metal ion free filling Suitable for warm fill products High chemical stability Low weight Good cleanability Needle testing and adjusting device 1 3 Thanks to its interchangeable needle holder, this device is suitable for all types of filling and gassing needles. For the different machine types (ampoules, cartridges, vials or syringes) only one device is needed. The handling of this device, which can be used flexibly and transported easily, is simple: after inserting the needle (1) in the holder (4), the slide (2) is moved towards the needle. The interchangeable centering pin (3) checks the concentricity of the needle by turning the holder. If necessary, the needle is readjusted and subsequently double-checked in the device. 4 2 Defective and/or bent needles can thus be straightened and used again. You therefore do not have to obtain new needles, which saves you money on new parts. By regularly checking your needles, you can ensure constantly high productivity and quality with the filling and gassing by your machines. Reject and downtime of your machines by defective needles are avoided. Your benefits Versatile use of the device High process safety of your equipment Increased productivity Lower reject rate and less downtime Cost savings

10 10 Bosch Packaging Services Filling needle monitoring upgrade The filling needle monitoring upgrade can be implemented on the machine types FLP, FLC, FLM, MLD, MRD, MLF and MRF. reflector sensor Sensor and reflector with laser beam This upgrade kit for the filling station consists of a sensor and a reflector. In addition, new filling needles are needed for the modification. The filling needle monitoring ensures that the machine stops immediately if a needle does not hit the object and is therefore pushed up. Due to the incorrect position of the filling needle the laser beam between the sensor and the reflector is interrupted, and the safety mechanism is thus activated. This safeguard minimizes the risk of damage on the filling needles. Contamination of the machine with product as well as incorrect filling due to defective needles are reduced or avoided respectively. The upgrade can therefore be recommended especially if expensive and high-quality products are filled. The upgrade by a Bosch fitter, including programming changes, will take no longer than 1 working day. Your benefits Filling needle pushed up Increased production reliability Reduced risk of incorrect filling Prevention of contamination with product Simple upgrade

11 11 Bosch Packaging Services Bottom-up filling For optimizing the filling process especially with heavily foaming products, the filling needle lifting cam is adapted exactly to the filling volume and the object (synchronously ascending movement). If different ampoules / vial sizes are run on a machine, the following parts are needed for the bottom-up filling: filling needle lifting cam, synchronously ascending with filling level, with flange and eccentric bolt (depending on object and filling volume) pump stroke cam (required one time) filling needles (depending on object) Advanced TPF (Time-Pressure Filling system) control system The TPF (Time-Pressure Filling) control system has been developed further and is replaced by an new system. For older systems some of the components are no longer available. Please ask for our separate upgrade information. Filling needle lifting cams The filling needle lifting cam synchronously ascending with the filling level makes the filling needle insert into the object until it reaches the object bottom. Then the needle ascends with the rising filling level, thus largely preventing the product from foaming. Pump stroke cam A new pump stroke cam is assigned to the different filling level cams for the bottom-up filling. 1/3 Filling The filling needle is directly at the object bottom until one third of the object is filled The filling process starts slowly 2/3 Filling The filling process in the product is getting faster and accelerated continuously until the end. The filling needle is below the filling level until the end of the filling process. Filling needles Longer filling needles are required. This upgrade can be implemented on old machine types as AVR, ALK and FLP.

12 12 Bosch Packaging Services Peristaltic pump Thanks to the newly developed large pump head, volumes up to 500 ml can now be filled with the Bosch peristaltic pump (also called hose pump). The large pump head is suitable for filling volumes from 20 to 500 ml. In addition, a smaller filling head is also available for filling volumes from 0.1 to 30 ml. Together these two sizes cover an extensive filling range and are characterized by high filling accuracy. Another ground-breaking innovation is the detachable version of the pump heads. The two pump head sizes can be swapped quickly and easily, as production requires. The tool-less replacement can be carried out with one hand. A distinct advantage of the detachable version is that it is much simpler to clean. All types of the Bosch peristaltic pumps, both for single and multiple-use dosing systems, are used in connection with platinum cured silicone hoses. The easy handling of the product path (hoses etc.) on the pump is very user-friendly. Furthermore, the product loss is very low due to minor dead volume during start-up and run-empty. All peristaltic pump versions and sizes are available as a stationary pump station mounted on the machine or a flexible solution on a moveable trolley. Hose for peristaltic pump The use of a correct hose is essential for the proper functioning of the peristaltic pump. Whilst working to enhance the peristaltic pumps, Bosch also focused on optimizing the hose quality. After extensive tests, a compliant hose was developed, manufactured in platinum-cured silicone, with FDA conformity acc. to CFR and USP class VI. The use of this Bosch-specific hose, which can be obtained exclusively from Bosch, ensures adherence to filling tolerances and functional reliability. In addition to the benefits of using it for the peristaltic pump, it is also ideally suited as peristaltic hose in the Time Pressure Filling System (TPF). This hose is available in 5 m and 15 m units. On top of the spare parts number and the inner diameter it is marked with small for the 0.1 to 30 ml or large for the 20 to 500 ml pump head.

13 13 Bosch Packaging Services Hose cutting device for cutting peristaltic hoses to the required length Hoses for peristaltic pumps are usually sold by the metre and therefore have to be cut to the required length. With the new Bosch hose cutting device all hoses with an outer diameter between 2.9 and 14.3 mm can be cut quickly and easily. The working area ranges from a length of 50 to 270 mm. The device consists of: Your benefits Quick and precise cutting to size of hoses Easy exchange of Bosch standard cutting unit Handy size Base plate Scale ruler (not calibrated) Variable end stop, lockable in position Bosch standard cutting unit The device comes with 10 replacement blades for the cutting unit.

14 14 Bosch Packaging Services Enhanced filling level sensor at product tank With the tri-clamp seal the new capacitive filling level sensor ensures maximum tightness during autoclaving, even after a large number of autoclaving cycles. In addition, better sealing towards the product is ensured during the filing process. For the tool-less assembly tri-clamp seal 1½ part no as well as the tri-clamp seal part no are needed. For the newly developed sensor a new sensor amplifier, part no , with angled connector is available. The amplifier is supplied with cable part no The cable plug connection allows for easy assembly. With the scaled and detachable turning knob at the sensor amplifier the switching threshold can be adjusted precisely and without any tools, i.e. a screwdriver is no longer needed. The set value is maintained by simply removing the turning knob. The amplifier comes with status LEDs to visualize the switching status and error messages. The switching status opening/closing can be set via a wire connection, so the previous risk of mixing up the setscrews is excluded. The new filling level sensor can be used with both the new and old amplifier part no For the easy upgrade of the product tank with the new filling level sensor a modification kit consisting of sensor adapter x threaded pin is available. For mounting the sensor the standard ports at the product tank can be used. Changes in the electrical system and software are not required Filling level sensor Sensor amplifier, pluggable version Cable for sensor amplifier You will find your local partner at: 02/2016 PA-CS/STP2 Bosch Packaging Services AG (subject to alterations)