Machine Training

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Training Overview

When utilizing a Genesis Packaging Technologies crimping machine as the primary means of applying overseals to parenteral vials, an understanding of the proper setup of the mechanical variables related to sealing rail technology is necessary in achieving proper high quality package sealing. Likewise, comprehending and controlling the interaction of the following process related categories is integral in creating both an aesthetically appealing and mechanically sound container closure:

1. Process Package Components – Vial, Stopper, Seal
2. Vial Change Parts
3. Cap Change Parts
4. Setup Adjustments

The relationship of these four major subdivisions as relates to seal integrity needs to be considered and each area addressed appropriately in order for the crimping machine to be used effectively.

Details of the relationship of these four subdivisions are provided in the Genesis Packaging Technologies Training Program.

1. 1

   Process Package Components

   The quality of package components to be processed by the crimping machine is directly related to seal integrity. Genesis Packaging Technologies highly recommends that only high quality vial package components be processed through its machinery. While the crimping machine can accommodate some degree of component variability without sacrificing seal quality, batches which exhibit large variations in vial dimensions, overseal skirt dimensions, and stopper hardness qualities can profoundly affect seal integrity. Vial height dimensions and stopper characteristics directly affect spring compression; vial finish and overseal skirt length directly affect the aesthetic and mechanical integrity of the seal, and relatively liberal tolerances in vial neck dimensions can result in scored or broken vials. Each time the crimping machine is initially setup, the package components used in this procedure are generally considered to be representative of the overall quantity of components to be processed. Generally speaking, manufacturer component tolerances which are generous in scope can result in variations outside of a reasonable deviation window and will result in intermittent substandard sealing and, oftentimes, a manufacturing process which is out of control. Utilizing high quality package components whose manufacturers have controlled and minimized this variability will result in a repeatable and streamlined crimping process whereby quality sealing is virtually guaranteed.

   A detailed study of how vial components relate to seal integrity is provided in the Genesis Packaging Technologies Machine Training Program.

2. 2

   Vial Change Parts

   Vial change parts are responsible for directing the flow of vials through the crimping machine. Genesis Packaging Technologies recommends employing only genuine OEM manufactured vial change parts on its capping machines. Vial change parts are engineered and manufactured to exacting tolerances that provide the correct interplay of these components along the vial path throughout the sealing process. The use of correctly machined vial change parts as relates to seal integrity and a consistent sealing process cannot be overstated. Infeed and discharge screws, infeed, discharge, and eject starwheels and starwheel guides, infeed and discharge fixed pin guide rails – all of these vial change parts are designed utilizing decades of engineering experience in sealing rail technology vial transfer. Proper setup and proper maintenance of vial change parts are required in order to maintain consistency in capping machine performance. When coupled with high quality vial package components, correct OEM vial change parts insure a repeatable and maximized throughput on the crimping machine.

   A detailed study of vial change parts selection and setup is provided in the Genesis Packaging Technologies Machine Training Program.

3. 3

   Cap Change Parts

   Cap change parts incorporate both the cap delivery system and the sealing rail assemblies. Genesis Packaging Technologies recommends employing only genuine OEM manufactured cap change parts on its crimping machines. In the same manner that vial change parts are engineered and manufactured to exacting tolerances so too are the cap change parts manufactured with great attention to precise dimensional detail. These components provide vials to be processed with a streamlined, uninterrupted flow of overseals and are ultimately responsible for creating the finished product seal. The use of correctly machined cap change parts as relates to seal integrity and a consistent sealing process, once again, cannot be overstated. Cap trays, cap chutes, cap feeds, pressure blocks and sealing rails – these cap change parts are designed with the full advantage of decades of engineering experience in sealing rail technology. Proper setup and proper maintenance of cap change parts are required in order to maintain consistency in capping machine performance. High quality vial package components, correct OEM vial change parts and correct OEM cap change parts are the essential building blocks upon which an integral sealing process is ultimately built.

   A detailed study of cap change parts selection and setup is provided in the Genesis Packaging Technologies Machine Training Program.

4. 4

   Setup Adjustments

   Setup adjustments are critical to the operational integrity of the Genesis crimping machine. Genesis Packaging Technologies recommends a strict adherence to established setup procedures. Exploiting the full potential of the crimping machine can only be realized if there is a precise observance of these recognized steps. This observance allows for consistency in process as well as assured seal integrity.

   The areas of setup can be divided into the following categories:

   1. Vial Change Part Setup
   2. Cap Change Part Setup
   3. Machine Head Height Setup
   4. Spindle and Vial Rest Spring Setup

   
   

   Critical measurements are captured at various stages of setup and, once recorded, these measurements are used to streamline subsequent setups. By dedicating vial and cap change parts to specific vial packages, setup becomes a matter of installing change parts and re-establishing simple parameters. This reduces downtime, increases production and maintains a process in which seal integrity has been proven.

   A detailed study of crimping machine setup procedures is provided in the Genesis Packaging Technologies Machine Training Program.