IMA set to draw crowds with 1,100 square metres of innovation

The IMA group is exhibiting a range of new equipment for the processing and packaging of pharmaceutical products on its huge 1,100 square metre stand, F49 in Hall 3, at this year's Achema.

The high precision technology of IMA’s machines and complete lines will be displayed in minute detail via jumbo screen video walls.

Visitors will also have the chance to visit the Process Innovation Hub, a corner dedicated to novel process technologies. A breakthrough integrated continuous manufacturing (ICM) technology for small molecule pharmaceuticals, where the synthesis of the active ingredient and the final dosage form are integrated into a seamless process, will be highlighted. This novel method allows on-demand manufacturing of pharmaceuticals with significant advantages in production lead time, quality and costs.

The Process Innovation Hub will also offer the opportunity to share new ways to design freeze dryers and innovative processes with regard to accelerating freeze-drying. Ice-fog nucleation and spray freeze dryers are gaining ground. 

IMA ACTIVE SOLUTIONS ON SHOW

MYLAB is a recently launched piece of equipment, designed for R&D and scale-up purposes and suitable for both granulation and coating processes. It consists of a main technical unit (MTU) with fully integrated air handling unit and control panel, connected to a removable processing module, represented either by a coating pan or by a fluid bed processor. The coating pan processor is equipped with an interchangeable and fully perforated drum able to work batches from 1.5 to 6 litres. The fluid bed processor has interchangeable product containers for top or bottom spray processes, which can run batches from 2 to 6 litres, meaning MYLAB offers maximum flexibility and easy scale up for small production batches. Characterised by small overall dimensions, MYLAB is portable on wheels and can be easily and quickly connected to utilities.

ADAPTA 200 is a high-speed capsule filler, a combination of quality and process technology born from knowledge and experience. This machine allows for the dosing of up to three products into the same capsule without affecting the maximum speed of 200,000 capsules/hour. Its dosing units can be easily removed and are reversible/interchangeable, giving the possibility of a plug- and-play shift between different machine configurations and filling combinations. ADAPTA 200 can achieve the 100% control gross and/or net weight, integrated with automatic feedback on machine parameters and rejection of out-of-limits capsules.

Both MYLAB and ADAPTA feature the XIMA HMI. The system has been awarded the A’ Design Award for its application of design principles with the aim of improving user experience. Based on the four principles of linearity, intuitiveness, iconicity and scalability, the HMI plays a strategic role in improving operators’ efficiency, granting prompt responsiveness, enhanced process knowledge and predictivity, as well as easy learning for new operators or between different machines.

The SPINE HYPO is the new SPINE machine with containment design for automatic inspection and sorting of highly potent tablets and capsules. It features containment strategies, such as separation of process area with barrier, negative pressure, air filtering, gloves, RTS ports, closed feeding and discharging and last but not least, dry and wet cleaning in containment.

IMA will also present the new PATVIS APA in-line control system produced by SENSUM. PATVIS APA is a process analytical technology visual inspection system for monitoring, understanding and optimisation of fluid bed pharmaceutical production processes. This system enables real-time monitoring and fully automated analysis of size and shape of particles throughout processing. It is portable and can be easily integrated to existing viewing ports for in-line inspection or used as a standalone device for at-line or off-line inspection.

IMA LIFE SOLUTIONS ON SHOW

Among the new solutions on display from IMA LIFE is the filling and stoppering of ready-to-fill disposable syringes. Compliant with the most recent cGMP and FDA regulations, the machine is tailored to the latest requirements of the pharmaceutical and biotechnology industry in the aseptic filling field.

The ready-to-fill pre-sterilised syringes are inserted into nests of 160 pcs/each and automatically handled by sterile plastic tubs. The machine is equipped with a 100% check weighing group, for net and gross weighing before/after filling and final relocation inside the nest. The syringes are filled and then stoppered five at a time. Dosing units and stopper pick and place arm are driven by brushless motors. Ceramic/st.st. rotary piston pumps or other types of filling systems suitable for aseptic environments, such as peristaltic pumps, can be easily installed. In case of viscous product to be filled or where air bubbles can be possibly foamed during dosing, the machine can be equipped with a special vacuum filling system. The machine is conceived to dispense liquids and stoppers either in conventional cleanrooms or under RABS or isolators. Controlled by a HMI with industrial PC, the machine can perform at speeds of up to 7,000 pcs/hour with 100% check weighing system or, without IPC, 12,000 pcs/hour. 

For the first time, IMA Life will demonstrate an innovative liquid filling and closing machine that alternatively processes RTF syringes, vials and cartridges. Designed for aseptic environments and suitable for barrier technology implementation, the machine is equipped with 100% IPC and can reach an output speed up to 1,300 pcs/hour.

Combining filling, stoppering and capping operations for a multiple range of different containers such as syringes, cartridges and vials, this machine offers the reliability of a fully automated production line, minimising  space and  preserving sterility requirements. Dedicated mechanised arms ensure the completely fully automated product transfer/handling operations. All types of dosing systems, suitable for aseptic processing, can be installed on the machine. This innovative compact integrated machine can be considered as a real answer to the current market trends in terms of sterile processing requirements and to the cGMP regulatory expectations and FDA guidelines.

IMA SAFE SOLUTIONS ON SHOW

The IMA SAFE division offers the advantage of being able to capitalise upon the experience of the other IMA divisions and is therefore able to satisfy all requirements for containment of solid pharmaceutical shapes in blister packaging. On show at Achema 2015 will be the GIANT blister packaging machine, which is equipped for the highest level of containment.

The new SWIFTPACK SP2-4 multichannel electronic counter for tablets and capsules has been designed with the experience gained after supplying more than 100 SwiftPharms throughout the world. Along with a smaller footprint and increased output, this new counter has an integrated conveyor controlled from a single HMI. Quick changeover components and the tabletop design further improve the machine’s ease of cleanability. The machine on show at Achema will also be equipped with the advanced counting technology E.F.S.

The new entry C80HS-A76 integrated blister line is designed especially for the production of medium batches and frequent size changeovers. Based on the success of the well-known blister lines manufactured by IMA SAFE, the C80HS-A76 reaches a production speed of up to 700 blisters/minute and 250 cartons/minute. The C80HS can also be connected with the A86 cartoner, able to reach 350 cartons/minute, and the A96 cartoner, able to run up to 500 cartons/minute. C80HS features a positive blister transport and an innovative blister cutting system.

Find out more about IMA’s innovation drive at Achema 2015.