interpack 2023: Syntegon showcases optimized solutions for the coating and sealing of solid dosage forms

Die Banderoliermaschine GKB 2100 versiegelt Kapseln unterschiedlichster Materialien zuverlässig und erzeugt so eine hohe Dichtigkeit. / The GKB 2100 banding machine reliably seals capsules of a wide variety of materials, creating a high level of tightness.

Das Human Machine Interface unterstützt Bediener:innen bei jedem Prozessschritt – von der Einrichtung des Coaters bis zum Reporting. / The Human Machine Interface supports operators in each process step – from coater setup to reporting.

Die Sepion Coater-Baureihe mit Trommelgrößen von 175 bis 1000 Liter dient zur Film- und Zuckerbeschichtung von Tabletten. / The Sepion coater series with drum sizes from 175 to 1,000 liters ensures the film and sugar coating of tablets.

– Sepion 175 coater: Human Machine Interface for intuitive operator guidance during setup, process and process monitoring
– Sepion 175 coater: Flexible coating solution for film and sugar coating of small batch sizes
– Banding machine GKB 2100: Gentle handling and sealing of hard gelatin and plant-based capsules

With the Sepion 175 drum coater and the GKB 2100 banding machine from Syntegon, visitors to this year's interpack will experience two essential process systems for solid dosage forms with optimized functionalities: The Sepion series with drum sizes from 175 to 1,000 liters was presented for the first time at the virtual interpack 2020. The versatile system for the film and sugar coating of tablets comes with Syntegon’s latest Human Machine Interface (HMI), an intuitive and modern solution for even easier process control and monitoring. In addition, the coater ensures significantly shorter process times thanks to increased spray rates as well as recipe-controlled, enhanced cleaning. With the GKB 2100 banding machine, Syntegon is responding to the growing demand for oncological therapeutics, phytopharmaceuticals and dietary supplements, as well as the trend towards vegan alternatives made from HPMC or pullulan. In addition to gentle handling, the GKB 2100 provides reliable sealing and drying, thus ensuring high tightness levels.

Sepion 175: Modern coater with intuitive controls

The new Human Machine Interface (HMI) is the digital control and monitoring centerpiece of various systems in Syntegon's machine portfolio. This is also the case with the Sepion 175 drum coater: From setup and recipe creation to process monitoring and reporting, the interface supports operators in each process step. For example, the HMI allows to easily initiate sampling during the coating process.

The distance between the spray nozzles and the tablet bed can also be specified in the recipe; the spray arm adjusts automatically. The coater even enables tracking of the spraying arm via optional laser distance measurement. “With the Sepion 175, we are specifically targeting customers who need a flexible and efficient coating solution for small batch sizes,” says Fritz-Martin Scholz, Product Manager at Syntegon. "The Sepion coater meets both requirements thanks to its modern control system and innovative drum design.”

The interface also provides easy access to Syntegon's digital service solutions - paving the way for greater overall equipment effectiveness: detailed information on essential OEE data, machine settings and alerts enables operators to plan preventive maintenance and thus reduce downtime.

In terms of end-to-end optimization, the core technological components of the Sepion 175 also offer coating benefits. A higher number of spray nozzles combined with an extended drum length results in a spray rate that is up to 40 percent higher than comparable established coaters. “As a result, the process times for film coating turn out to be shorter overall; however, the yield and quality of the coating remain unchanged at a high level,” says Scholz.

Optimized cleaning times

In terms of cleaning technology, Syntegon has made important changes based on comprehensive tests, leading to significant savings compared to benchmark coaters. “Operators can individually optimize the cleaning process via a flexible cleaning recipe. This enables manufacturing companies to use their cleaning agents and resources as effectively as possible,” explains Fritz-Martin Scholz. The coater thus contributes to more efficient and sustainable processes. A validated, reproducible recipe forms the basis for the entire cleaning process and minimizes manual operator intervention.

GKB 2100: Innovative sealing of hard capsules

Visitors to the booth will also experience the new GKB 2100 banding machine for sealing hard gelatin and cellulose-based capsules at an output of up to 125,000 pieces per hour. “The liquid-filled capsules of both materials require additional sealing, known as banding, to seal them tightly,” explains Matthias Mössinger, Senior Market Expert Pharma Solid at Syntegon.

The gentle handling of the capsules poses another challenge. To avoid crushing during feeding into the sealing area, Syntegon relies on an automatic and extremely gentle roller feed system. Sealing rollers apply the sealing liquid in two layers in two independently controlled stations before capsules enter the drying module in up to twelve tracks. In this area, the applied band dries in segmented zones by means of conditioned air.

The easily accessible machine offers maximum ease of operation, which ensures the best possible cleaning, as well as simple format or product changeovers. If required, Syntegon not only supplies the right machine including detailed process advice – thanks to the full-service approach, the expert teams in the Waiblingen laboratory also precisely match the sealing liquid to the product to be filled and the empty capsule.

Service Agreements: Support at fixed prices

Just like for all Syntegon equipment, Syntegon’s redesigned Service Agreements will be available for the drum coater and banding machine. The Service Agreement packages ensure customers effective asset and maintenance management at fixed costs. Seven dedicated Service Agreement levels help customers from the pharmaceutical and food industries to reduce production risks, gain predictability over service costs and simplify complex processes – enabling them to focus on their core business. With each level, customers receive support, from basic service including inspection and remote service to guaranteed production performance for their machines. The Service Agreements provide customers with ease of mind regarding their equipment’s overall lifetime costs from Level 4 upwards. Besides planned maintenance and operator training, services at this stage include all parts at fixed costs to make this promise a reality.

One essential aspect of the Service Agreements is Synexio, a new cloud-based software solution for the acquisition, evaluation and visualization of equipment and production data. Syntegon will release three consecutive packages of Synexio, with the entry-level package “Monitor” available for the Sepion and GKB as well. This package visualizes various KPIs to help companies achieve transparency over their production. At this year’s interpack, Synexio’s follow-up package “Uptime” will be launched, enabling customers to understand machine performance and identify improvement potentials.