Doyen Improves Transdermal Patch Converting And Packaging System

Jan. 11, 2010 - PRLog -- Doyen Medipharm, of Wymondham, Norfolk, has many years experience supplying converting systems for transdermal patches to the pharmaceutical industry. Over the past years, their proven production technology has been further developed to achieve higher production speeds and efficiency for manufacturers looking to fulfil the growing demand for pharmaceutical, and more recently, cosmetic patches.

Last year, Doyen supplied the first system of this new machine generation to a customer in Europe. Capabilities of the improved transdermal patch manufacturing system (TMS) include multilane operation at speeds of up to 250 products per minute per lane and in-line packaging into sachets by a HMI controlled platen sealing unit.

The system converts a product base web, usually consisting of a drug adhesive layer coated onto a film and carried by a release liner, into individually wrapped transdermal patches. Two die stations kiss cut the release for easier removal of the liner by the patient, and the shape of the patch. Ladder waste is then removed. Web optimisation features enable high cutting precision and maximum material utilization. “Handling delicate, stretchy or sticky materials at speed with a high degree of accuracy is very important in any converting process,” says Neil Andrews, Doyen’s VP of Sales and Marketing. “However, the drug laminates used in transdermal patches are very expensive, so that it is a priority to keep waste to a minimum. To this end, Doyen also offers the option to produce without ladder waste.”

The web is slit to form the required number of lanes, which are separated to the pack width and transferred to the patch cutting station. Here the patches are cut and directly transferred onto the packaging web, spread according to its pitch. The lower packaging web is statically charged to attract the patches and provide an accurate positioning as they are transferred from the anvil.

A vision system for quality control purposes inspects the products before the top packaging web is introduced. Any faulty patches or pouches deemed to be outside of the acceptable tolerances for manufacture and validation, i.e. misplaced or missing product, are discarded at the integrated reject station. Intelligent HMI controlled reject is not only able to discard sachets on an individual lane basis, but can also sort the rejects into separate bins or extract random samples for quality control purposes. “Constant quality control is vital when active drugs are concerned, as flaws in the in the integrity of the patch can put patients at risk”, explains Andrews.  “It is important for Doyen to work with customers and suppliers to integrate sensor and camera control to achieve superior levels of quality and product safety.”

The packaging webs are sealed by a continuous motion platen seal station. The platen sealer is an improved design, aimed at achieving high throughput while facilitating tooling changes. “In the endeavour to make production more effective, extended downtime at changeover between sizes is a problem,” knows Andrews. “The improved design does not only include lighter tooling that is easier to exchange; the tooling is also available at lower cost, which offers a long term benefit to our customers.” As a further advantage, the platens are lifted from the packaging material during machine stops to avoid overheating the packages or damage to the platens.

With the pressure to achieve higher line speeds and performance, automation has moved into the focus of many manufacturers. All Doyen systems offer the option to integrate product and packaging web printers, vision inspection systems and end-of-line stacking, collating and cartoning modules to increase productivity. “If a line converts, packages and stacks the products for cartoning in the same process, with a minimum of downtime for changeovers, the manufacturer does not only reduce human labour, but also improves quality.”    

The machine is controlled via a colour touch screen, and driven from a recipe based control system. Recipes are password protected and validated. Operators load a validated recipe that automatically adjusts all the control system parameters. A list of mechanical settings and tools guides the operator to complete the product set up.

Doyen Medipharm is a leading specialist supplier of Converting and Packaging machinery for the medical and pharmaceutical industries. Apart from production lines for transdermal patches, the company offers fully integrated converting and packaging lines for wound care products and medicated oral film strips, as well as walleting and packaging equipment for gloves and medical devices.

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Doyen specialises in medical and pharmaceutical Converting & Packaging machiners. Doyen offers fully integrated lines for wound care products, transdermal patches & medicated oral film strips, and packaging equipment for gloves & medical devices.