When it comes to an ampoule filling and sealing line from the German company Bausch+Ströbel, built, as our grandfathers used to say, “to last forever”, restoring it is a matter of time — and, of course, the result of the knowledge and skills of AT Engineering’s specialists.
We received the line in non-working condition.
The photos clearly show the entire modernisation process.
The condition we found:
- the configuration did not match a working machine;
- the main electric drive did not match the required machine output;
- synchronisation of the main assemblies and mechanisms was lost;
- the ampoule conveyor was missing;
- the ampoule discharge receiver was missing;
- the ampoule sealing mechanism was not working;
- the gas and oxygen supply system did not meet technical requirements;
- the drive gears of the ampoule acceleration rollers were damaged;
- the bearings for transporting ampoules around the carousel were corroded;
- the gas pressure regulation system was faulty;
- the production counter mechanism was faulty;
- dosing needles and dosing pumps were missing;
- the equipment protection and interlock systems were faulty;
- all parts and mechanisms of the line were affected by corrosion and wear;
- the lower protective doors of the mechanical section were damaged.
Everything started with assessing the wear of the mechanical parts and the condition of the electrical and electronic components. The next step was planning the work.
AT Engineering specialists carried out a complete overhaul of this Bausch+Ströbel ampoule filling and sealing line:
- main and auxiliary drive gear motors meeting Bausch+Ströbel requirements were selected;
- all rolling and plain bearings were replaced;
- all gas and oxygen piping on the line was replaced with piping that meets technical safety requirements;
- the automatic ignition and flame maintenance system for ampoule sealing was changed;
- an ampoule infeed conveyor was designed and manufactured;
- the paint coating of the entire line was restored (chemical- and heat-resistant);
- the lower guarding of the line was restored;
- synchronisation of the main assemblies and mechanisms was restored;
- an ampoule receiver meeting the customer’s requirements was manufactured;
- the gas regulation and supply system for ampoule sealing was improved;
- ampoule sealing was set up precisely and correctly according to specifications;
- a burner gas extraction system was installed;
- change parts for the line were designed and manufactured (augers for 2 ml formats, discharge guides, ampoule infeed star wheels, etc.);
- commissioning was carried out (professional installation and commissioning guarantee trouble-free operation);
- staff were trained directly at the customer’s production site.
The equipment can now run at up to 18,000 ampoules per hour without any loss of product quality.
It is hard to believe this is the same old line. Old pharmaceutical equipment can have a new life if it gets into the hands of specialists. AT Engineering repairs and modernises production lines for the pharmaceutical industry. A key focus of our engineering service is 24/7 technical support for our customers.
AT Engineering also supplies dosing pumps for this Bausch+Ströbel filling and sealing line and offers spare parts kits.