人与机器专家
成功案例 03.12.2020

Stericlean无菌机器人用于玻尿酸灌装生产

易于编程的无菌灌装

概述

一家瑞士工厂制造商以玻尿酸灌装生产线树立了行业标杆。该系统的核心是史陶比尔Stericlean无菌机器人,它在无菌条件下向预充针中注入这种抗衰老物质。 史陶比尔六轴机器人的uniVAL plc接口允许通过西门子PLC进行方便和直接的编程。

玻尿酸(透明质酸)被广泛认为是美容业的奇迹疗法,是皮肤真正的青春之泉。 仅一克基本成分的玻尿酸就可以凝结六升水,能针对性地为皮肤补充和储备水分,使皮肤更具弹性。

玻尿酸的市场需求量非常大,Zellwag Pharmtech AG公司专门为这种产品开发了一套全自动灌装和封装生产系统。该系统需要机器设备在洁净室条件下工作,向预充针中注满玻尿酸凝胶,然后将其密封。这两种过程必须在真空下进行,如果将空气混入凝胶极其危险,必须完全避免空气进入。

Zellwag公司总部位于瑞士,专业研发用于制药、医疗和日化品行业的灌装和封装系统。Zellwag因其客户专用多规格工厂的规划和建设而闻名,并因其节约资源的系统和高度自动化功能而被熟知。

在为化妆品制造商设计生产设备时,Zellwag工程团队的首要任务是确保在无气泡条件下进行混合、挤压和填充。在整个过程必须在真空条件下进行,设备将凝胶安全地输送到灌装线,挤压机中绝不能混入一丝空气,因为如果凝胶中有空气会给用户带来危险。该系统采用史陶比尔Stericlean无菌机器人,它在无菌条件下向预充针中注入产品。

机器人进行无菌灌装

得益于史陶比尔 TX2-90 Stericlean 六轴机器人出色的性能,可以设计出节省空间的布局来处理预充针、西林瓶和巢盒。一个装有100支无菌预充针的Tyvec密封缸被送达机器人的工作区域,线性系统将Tyvec上的箔片剥离,然后第二个线性系统将预充针取出。

机器人抓取装有预充针的容器,将其旋转90度,将其送到填充站。然后一次填充两个预充针,将凝胶从喷嘴中挤出。经过50次循环后,所有的预充针均已装满。高动态性能的Stericlean机器人将它们放在蜂巢盒中,蜂巢盒通过输送机系统输送到下一步处理站。

灌装速度达到了每小时2200支预充针,由于凝胶粘度因素限制,机器人尚未达到最高速度。对于水性介质,史陶比尔机器人每小时最多可进行6000次填充操作。

史陶比尔Stericlean机器人的洁净设计用于无菌环境。

专为无菌环境定制的机器人

整个过程在无菌环境中进行——在这种条件下使用传统机器人是难以想象的。然而,史陶比尔独特的Stericlean无菌机器人在这样的环境中却可以运行自如。该系列产品是专门为GMP A级无菌生产领域的关键应用而开发的,并已被成功验证了数千次。

Stericlean六轴机器人的外观是完全密封的,电缆在内部走线,表面光滑无死角,没有形成杂质的空间。 这些性能出色的制药机器人能够抵抗苛刻的常规灭菌和去污程序,例如使用过氧化氢灭菌等。

控制系统集成方式提高编程效率

Zellwag公司采用西门子的TIA平台控制应用和系统,史陶比尔TX2系列机器人的uniVAL plc接口可以和包括西门子在内的所有编程逻辑控制器进行配置。由于消除了复杂子系统和接口,因此该集中式系统不仅大大减少了编程输入,而且提高了灌装线的功能和效率。操作员可以继续在熟悉的环境中工作,不必学习新的机器人编程语言。 在安装后,它也为过程适应和格式扩展提供了最佳条件,并且能够应对数据采集、处理和鉴定方面日益增长的新需求。

利用uniVAL plc对机器人进行方便的编程。

Zellwag公司自动化团队经理Ahmad Asraf非常认可这种集成解决方案的优点:“通过集成史陶比尔机器人应用程序使系统编程变得更容易。当我们为首套预充针灌装系统设计编程时,该应用程序就为我们节省了30%的时间。对于额外分配给系统的每个嵌套式容器,我们现在的处理速度是以前的两倍,同事们都很认可这种集成解决方案。”

借助史陶比尔Stericlean机器人,Zellwag能够在无菌条件下、紧凑空间内以高度灵活性和最少编程的工作量实现用于玻尿酸灌装的完美解决方案。 该机器人设计的洁净标准符合制药要求,而且uniVAL plc接口提供了必要的先决条件。

观看视频

在此应用中,六轴机器人平稳且高精度的运动轨迹尤为重要。
Stericlean无菌机器人用于玻尿酸灌装生产
TX2 stericlean机器人亮点:
  • 结构紧凑,优化工厂布局
  • 洁净设计用于无菌环境
  • 高精度且平稳的运动轨迹
  • 集中编程,增强功能和效率

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