Vial Packing-Cartoner Solutions for Food

We deliver comprehensive validation packages including IQ/OQ/PQ protocols, HACCP documentation, and food safety plan templates. Our support includes 72-hour installation supervision, 40 hours of operator training, and 24/7 remote monitoring with ≤2-hour response time. Customer data shows ≥98% equipment uptime and 100% audit success rate across FDA, BRC, and SQF certifications.

We've developed specialized filling technology for viscosities ranging from 50-20,000 cP and particulates up to 25mm. Our positive displacement pumps with servo control achieve filling accuracy of ±1.2%, while product-friendly valves prevent damage to delicate ingredients. Validation across 50+ product types shows consistent performance with Cpk ≥1.73 for fill weight control.

Our systems achieve energy consumption of ≤0.12 kWh per kilogram through IE5 premium efficiency motors, heat recovery systems (45% efficiency), and smart power management. Real-time monitoring shows base load of 28 kW with peak demand of 52 kW, representing 42% reduction versus conventional systems. We provide ISO 50001 energy certification with detailed consumption analytics for sustainability reporting.

We provide complete traceability systems capturing >200 parameters per package with 21 CFR Part 11 compliant data integrity. Our MES integration enables real-time monitoring of HACCP critical control points, automatic lot code verification, and instant recall management. The system generates automated compliance reports for FDA, USDA, and BRC standards, reducing documentation time by 85%.

Our multi-technology inspection system integrates 5MP color vision (detecting defects ≥0.3mm), X-ray detection (sensitivity: 0.5mm metals, 1.2mm glass), and laser-based seal inspection. The system achieves ≥99.98% defect detection with false rejection rate <0.008%, validated using certified test standards and continuous statistical process control monitoring throughout production.

Our automated changeover system enables complete transitions in ≤8 minutes through recipe-driven automation, motorized adjustments, and RFID-tagged tooling. The system stores ≥300 product recipes with automatic parameter recall, achieving immediate production readiness with weight accuracy within ±1.5% from the first package. Validation across 1000+ change cycles shows ±0.4mm repeatability and zero product waste during transitions.

We offer certified compostable films meeting ASTM D6400 standards, recyclable mono-material structures, and post-consumer recycled content up to 70%. Our systems are optimized for bio-based materials while maintaining shelf life equivalent to conventional packaging - validated through accelerated aging studies showing ≤5% quality degradation over 12 months. Carbon footprint analysis demonstrates 40% reduction compared to traditional packaging solutions.

We implement comprehensive hygienic design featuring USDA-approved materials, automated antimicrobial spray systems (peroxide-based, 200ppm concentration), and UV-C treatment tunnels achieving 3-log pathogen reduction. Our closed-loop environmental control maintains ISO 14644-1 Class 6 air quality, with validation data showing <5 CFU/100cm² surface counts and <10 CFU/m³ air quality throughout production runs.

Our automated lines achieve ≥180 packages per minute with component placement accuracy of ±1.2mm. The system employs vision-guided robotics with 6-axis servo control, multi-head weighers achieving ±1% weight accuracy, and real-time quality monitoring that maintains Cpk ≥1.67 for all critical parameters. Production validation data from 10 million packages confirms consistent performance across varying product viscosities and textures.