Automatic High-Speed Bunding Machine

Our automatic high-speed bundling machine achieves a maximum speed of ≥120 bundles per minute with an OEE ≥90% in continuous three-shift operation. This performance is validated through 30-day continuous runs measuring: Availability ≥96% (achieved via quick changeover systems), Performance ≥98% (maintaining rated speed), and Quality ≥99.5% (ensured by precision detection systems). The machine maintains consistent speed through servo-driven technology with positioning accuracy of ±0.2mm, ensuring reliable high-speed performance in pharmaceutical production environments.

We guarantee film breakage rate ≤0.3% through our precision film tension control system that maintains tension within 15-50N ±2N. The system features real-time tension monitoring with automatic compensation, pre-stretching technology achieving 250% consistent stretch ratio, and temperature-controlled sealing jaws maintaining ±1°C accuracy. Validation data from 10 million bundles shows seal strength ≥15N/15mm using ASTM F88 testing methodology, ensuring perfect bundle integrity throughout distribution.

Our recipe-based quick changeover system enables complete format changes in ≤8 minutes using only standard tools. The system employs digital parameter storage for unlimited product recipes, motorized adjustments for all critical dimensions, and auto-calibration of detection systems. Changeover precision is verified through laser measurement systems ensuring ±0.3mm repeatability across all bundle sizes. Each recipe includes specific parameters for film tension, temperature, and compression force to ensure immediate optimal performance.

Our machine accommodates diverse materials through adaptive film handling technology with specific capabilities: PE films (15-30μm thickness range), PP films (12-25μm with specialized temperature control 140-160°C), and PVC films (requiring 120-140°C sealing temperature). The system features automatic material recognition and parameter optimization based on film characteristics, while maintaining consistent sealing quality across all materials with seal strength variation ≤±5%.

Our energy monitoring shows average consumption of 0.08 kWh per 100 bundles at maximum speed, achieved through: regenerative drive systems recovering ≥45% of deceleration energy, IE5 premium efficiency motors reducing base load to 18.5 kW, and smart thermal management cutting heating energy by 40%. The machine incorporates insulated heating chambers and efficient heat distribution systems that maintain temperature stability while minimizing energy waste during continuous operation.

We prevent product damage through gentle product handling system featuring servo-controlled compression with programmable force profiles (5-50N adjustable in 1N increments). The system includes real-time pressure monitoring and automatic force compensation for product variations. For fragile items, we employ soft-contact grippers and vibration damping technology that reduces impact forces to <2G. Validation data demonstrates product damage rates ≤0.005% even with delicate blister packs and cartons.

Our machine features full Industry 4.0 capability with OPC UA and Ethernet/IP interfaces for seamless integration with upstream and downstream equipment. The embedded IoT platform provides real-time monitoring of >150 parameters, while predictive maintenance algorithms analyze component performance. The system supports automatic data exchange with MES and ERP systems, enabling real-time production tracking and automated quality reporting with full 21 CFR Part 11 compliance.

We've implemented predictive maintenance technology that monitors component condition in real-time. Maintenance schedule includes: daily autonomous maintenance (10 minutes visual checks), weekly preventive maintenance (45 minutes for lubrication and verification), and comprehensive maintenance (6 hours every 6 months). Critical components like sealing jaws have documented service life of ≥20,000 hours, with automated maintenance alerts and guided procedures ensuring optimal machine availability and performance.

Our high-speed vision inspection system utilizes multiple 4MP CCD cameras with LED strobe illumination capturing images at 300 frames per second. The system performs 100% inspection for: bundle formation quality (detecting misalignments ≥0.5mm), sealing integrity (identifying seal defects ≥1mm), and print verification (validating batch codes with ≥99.98% accuracy). Advanced algorithms achieve defect detection rates ≥99.95% with false rejection rates ≤0.02%, validated using statistical process control methods.

We deliver complete validation packages including: Installation Qualification (IQ) with full component documentation, Operational Qualification (OQ) with predefined acceptance criteria, and Performance Qualification (PQ) protocols for three-batch consistency. Our documentation follows GAMP 5 guidelines and includes risk assessment reports, traceability matrices, and cybersecurity documentation. We provide 24/7 technical support with ≤4-hour response time for critical issues, backed by global spare parts network guaranteeing ≤24-hour delivery for essential components.