July 11, 2017 – NJM Packaging and OPTEL will be showcasing their track & trace solutions at Pack Expo Las Vegas / Pharma Expo, where NJM’s Trotter W pressure sensitive labeler will be integrated with OPTEL’s BottleTracker™. This integrated system achieves in-line serialization and facilitates accurate aggregation at secondary packaging on automated lines to maximize manufacturing efficiencies. It enables pharmaceutical manufacturers and contract packers to easily and affordably comply with traceability requirements.
NJM’s Trotter W labeler is dedicated to the wrap-around labeling of round containers at speeds of up to 150 bpm. It can be equipped with a thermal transfer and/or laser printer to print serialized 2D barcodes and alphanumeric codes, lot numbers, expiration dates and more onto preprinted pressure sensitive labels during the labeling operation. OPTEL’s vision system inspects the variable data on the web and the labels on the bottles, and an automated reject device removes any abnormalities from the production line. For customers that need higher speeds and/or to label other bottle shapes, NJM offers other labelers for integration with OPTEL’s BottleTracker.
After labeling, the BottleTracker marks the bottom of each bottle with a ‘unique identifier’ in black or UV ink using a continuous inkjet printer. OPTEL’s vision system verifies the components and associates each unique identifier to the serialized code. This approach facilitates precise aggregation at secondary packaging by enabling that downstream vision system to capture one image of the entire group of bottles. A group of bottles could comprise a bundle at the bundler or a layer at the case packer, with the unique identifier of each bottle in that group visible.
Compared to traditional ‘first in, first out’ aggregation systems, which track each bottle coming into the bundler or case packer, this NJM/OPTEL system reduces errors to improve compliance and maximize production efficiencies. It helps product manufacturers and contract packers ensure consumer safety and protect brand integrity by authenticating product pedigrees while limiting the risk of product recalls, litigation and settlements.
The Trotter W and BottleTracker can be equipped to handle various inspections, including the presence and placement of labels, topserts and sideserts. The NJM labeler and OPTEL BottleTracker seamlessly connect with the OPTEL systems whose job it is to verify, report and manage the serial numbers, including those associated with bottles that are rejected, reworked and reintroduced.
Upstream of the BottleTracker’s inkjet printer, cameras inspect bottle bottoms to verify that they have either no unique identifier or a valid unique identifier, which enables operators to reintroduce previously marked bottles that were rejected and reworked. Bottles with no unique identifier are marked, bottles with a valid unique identifier pass without being marked again, and improperly marked bottles are automatically ejected from the line.
The Trotter W handles cylindrical containers, including spray cans, from 1 to 8 inches (25 to 203 mm) in height and 0.5 to 4 inches (12.7 to 101 mm) in diameter as a standard, with up to 5 inches (127 mm) in diameter as an option. It can be changed over to handle a new container size in less than 15 minutes, with no tools required and often no change parts. NJM can equip this labeler with an optional wrap drum wheel or wrap belt to handle the widest range of container sizes. With a standard friction wheel infeed, the Trotter W achieves speeds of up to 120 bpm while the optional starwheel infeed and motorized rewind enable the Trotter W to label small containers such as vials at speeds of up to 150 bpm.
By dedicating the system to the wrap labeling of round containers, NJM maximizes the simplicity of the machine and offers a compact footprint that is only 4 feet (1.2 m) wide and 10 feet (3 m) long. High quality components, heavy duty construction, an open frame, raised bed conveyor and the servo driven label dispenser contribute to repeatable performance and low maintenance for rugged reliability.
An Allen-Bradley MicroLogix 1400 PLC controls the Trotter W’s machine functions, and an Allen-Bradley Panel View 800 HMI offers advanced features and simple programming on a 7-inch color touchscreen.
NJM offers a “total solution” approach that includes full validation support and turnkey line integration services to seamlessly combine best-in-class technologies, including serialized and aggregated production lines comprised of primary and secondary packaging through bundling. NJM’s world-class aftersales support includes standard and extended warranties, preventative maintenance programs and onsite installation, training, and ongoing service.
About NJM Packaging, “Powered by Pro Mach”
For over 100 years, NJM Packaging has been the proven packaging systems resource, unmatched for the innovation and quality of our equipment manufacturing, solid dose solutions, expertise in labeling, complete line integration and truly exceptional support. A one-stop source, NJM Packaging offers expert knowledge and experience from the earliest stages of planning through implementation and production, delivering competitive advantage and greater end-product value to our clients. Our customers include: pharmaceutical, nutraceutical, food, beverage, chemicals, cosmetic and personal care product manufacturers as well as contract manufacturers.