Tag filling

Pharmaceutical Manufacturers Turn To Form, Fill & Seal Technology For Single Dose Medication Packaging.

Growing demand for single dose pharmaceutical packaging, particularly for aseptically filled liquid medications, is creating an opportunity for form-fill-seal (FFS) technology suppliers like ORICS Industries.

Used for the aseptic packaging of ophthalmic products, respiratory (inhaled) medications, biologics and vaccines and other injectable drugs, FFS technology enables continuous, automated forming, filling and sealing of unit-dose liquid packs.

Package formats include ampoules, vials and bottles, and product sterility can be assured throughout the process. Benefits of FFS, versus glass packaging, include reduced waste and breakage and the elimination of product preservatives, which patients may be allergic to.

The FFS-30 is an inline, intermittent motion sealing system that forms real steroids trays, cups and pouches in real time from roll stock film.

By forming trays online, this system has the ability to save the user tens of thousands of dollars by eliminating the costs associated with purchasing and shipping pre-formed trays.

What’s more, with a simple tooling change, this flexible system is capable of creating multiple tray/pouch sizes and configurations.

Film may be flexible, semi-rigid, or rigid.

Final package may be ambient, vacuumed, gas flushed to create a gas/air filled package or vacuum gas flushed to create a true Modified Atmosphere (M.A.P.) package.

FS offers cost savings over conventional aseptic processing in glass. Traditional  filling and packaging requires many steps and individual machines for filling, stoppering and capping. In contrast, FFS requires one piece of automated machinery, and takes place in six seconds or less.

When used to manufacture products intended for subsequent sterilization, these machines may be installed within an environment that would normally be considered appropriate for the manufacture and filling of terminally sterilized products. If the machines are to be used for the aseptic filling of sterile products they are usually provided with a localized environment at the point of fill with Grade A air.

For many brands, horizontal form-fill-seal (FFS) equipment represents a significant investment. FFS machines can be the most expensive machine on the packaging line. To maximize return on the investment, companies re-purpose machines for packaging a range of products. This makes quick tooling changes an attractive feature.

Over the last few years, ORICS Industries has worked to ease changeover in our FFS-30 for changing package sizes. We understand that our customers have been looking for ways to make it more efficient.

The ease of changeover can depend upon how easy it is to get tools in and out. Tools are often heavy and require a lot of muscle to remove and replace. This can result in injury risks, such as strained backs, broken fingers, etc. The risk of damage to tools is also heightened.

Changeover varies in complexity. The change may simply be to the packaging material, maintaining the same packaging footprint. Or, an entirely new package size or style may be needed. The amount of tooling changes depends on the degree of packaging change.

Tooling that can be changed includes forming dies, sealing platens, and cutting knives. There are control issues that may need to be changed to accommodate different packages, such as changing temperature, pressure, and index length. And there are peripheral issues associated with things like lot coders and in-line printers to changeover.

Should You Change?

Many companies that employ FFS machinery do so because they want better productivity and lower costs. Higher volumes may justify a dedicated packaging line, thus obviating the need for routine changeover. A daily production on FFS could be more than 100,000 packages, depending on the product being manufactured. Thus, the goal is often not to change out tooling.”

There may be other reasons for foregoing changeover. Validation of FFS is directly tied into forming tooling, loading, printing, sealing, and cutting. This process, when properly done, can take up to a week or more per tooling set. Once this activity is successfully completed, manufacturers would not want to upset the apple cart by making changes. This is also reinforced by the fact that FFS runs are generally three shifts for many weeks, sometimes months.

A partial if not complete validation would be required every time tooling is changed out. Depending upon the actual situation, the cost of the re-validation could exceed the potential cost savings of ‘quick-change’ tooling.

Modified Atmosphere Packaging is the combination of an optimal blend of Nitrogen and/or Carbon Dioxide with in a high-barrier or Permeable package. A finely adjusted and carefully controlled gas blend is created to meet the specific respiration need for each packaged food product.

Yogurt cup Filling and sealing packaging machine.

Yogurt is one of the in demand product types in the fermented foods industry, so it is worth examining some of the issues associated with producing this product. ORICS Industries has many years experience and expertise in helping yogurt companies deal with industry specific issues.

Top 3 Issues For Yogurt Packaging

A grainy texture during fermentation

Fermentation time decreases when higher temperatures are set which means manufacturers can break, cool and package it faster. To some degree, it can be detrimental to the consistency or texture of the finished yogurt. Yogurt set at higher incubation temperatures can incubate to a grainy texture.

Faster acid production from the culture as it metabolizes lactose and ferments it into lactic acid can shock the inherent dairy proteins in the yogurt. Incubating yogurt at a high temperature may reach the break pH in a shorter amount of time. But the faster acid production from the lactic acid bacteria can shock the dairy proteins and make the finished texture grainy in the incubation vat or in the cup, if it is set in the cup.

Setting the yogurt at a lower set temperature will produce acid at a slower rate, with less probability of shocking the dairy proteins.

 Yogurt is too tart

Yogurt that is too tart is counter to any marketing objectives. How does this yogurt become too tart? Manufactures sometimes disregard anticipating at what pH the yogurt should be broken and cooled. Manufacturers often need to break the yogurt at a higher pH in order for it not to go below the desired pH by the time the yogurt is packaged in the retail cup, cased, stacked and cooled in the cooler.

The solution to this problem is to simply raise the break pH to allow less of a pH drift downward by the time the yogurt has cooled, been mixed with any added fruit and sugar, and it is finally cooled down in the finished retail package.

A grainy appearance

A grainy appearance is often cause by starch selection. Many starches can have a grainy texture if they are not fully cooked out and swollen. Starch exists as tiny “granules” that swell and enlarge in size, which develop viscosity as they tie up or bind the available moisture in the dairy product. Milk contains 87% water, and plain sweetened yogurt in fact would have about 76% available water, depending upon the fat level and the total solids level.

Under cooking the starch can result in a grainy texture in the finished yogurt. The yogurt will have a coarse look to it. It may appear dull and not have a shiny look to it as well.

Choose another starch or increase the cook-out temperature of the starch by pasteurizing the yogurt at a higher temperature. If the starch is part of a stabilization system, it may be necessary to work with your supplier to change the starch portion in the yogurt stabilizer if you feel a smoother starch is necessary.

Cultured dairy products are complex and require strict attention to detail in order to have the best-quality product your dairy can produce and put in front of the consumer.

ORICS has designed many machines and systems to help yogurt manufacturers deliver consistent, quality results in the product quality, taste, texture and shelf-life.

ORICS automated yogurt cup filling sealing machine, full packaging solution for yogurt cup.

All ORICS Machines are engineered and fabricated in our Facility at 240 Smith Street Farmingdale, NY.

Tel: 718-461-8613

ORICS Mixed Nuts packaging machine, filling and sealing line.

At Orics we provide a wide array of packaging solutions for dry goods including nuts, seed, dried fruits and vegetables, chips snacks, candies, coffee, tea, non-dairy-creamers, cereal, granola, oatmeal, grains and much more. We feature an extensive catalog of denesters, fillers, sealers, form-fill&seal machines and turnkey systems.

Orics Mixed Nuts Packaging filling sealing machine.

Solutions For Fresh Fruit And Produce Packaging

Packaging fresh fruit and produce presents unique challenges for suppliers. Today’s supply chains are becoming longer and more complicated – and sometimes span several continents. The right choice of logistic services can determine whether or not a fresh produce consignment can be sold. Fresh produce can be shipped by sea, air, road, or in some cases, by rail. It is important to ensure that the delivery process and the packaging of fresh produce on its way from farm to point of sale is adapted to the respective mode of transport.

Packaging not only needs to be leak-proof (for convenience and hygiene purposes) and include machine-readable labels. It should also protect against contamination, so that fresh produce can be transported together with FMCGs in the same consignment. In this context, fresh fruit and vegetable packaging will increasingly be expected to support eco-sustainability, for example, by extending shelf life and using more eco-friendly materials. Growers will either need to expand their in-house packaging capabilities and processes, or enter into partnerships with service providers. We already see the packaging industry ramping up its production capacity for producers – and this trend is likely to continue as online sales increase.

ORICS is a leader in Modified Atmosphere Packaging, (M.A.P.) systems which helps to solve a number of issues for produce and fresh fruit with regard to ensuring freshness and prolonging shelf life.

Cherry Tomatoes Snack Tray Filling sealing Machine.

lunch Snack stan max for school or work, this tray filling and sealing is done on ORICS S-30, Denest,weigh, Fill and Seal. each tray contain 3oz of cherry tomatoes, candy tomatoes or tomatoes Bonbons.

different varieties of vegetables including celery, carrots, broccoli, sugar snap peas, grape tomatoes and raisins. These snacks are a healthy box of veggies; perfect meal replacement option. Ideal for all ages, from kids to adults. Packed 6 trays per carton.

visit Our Video page for all of our machines and food Ideas.
Like all Orics machines also this S-30 is US made at our New York Facility.
ORICS: 240 Smith street, Farmingdale NY 11735.

718-461-8613

diced sliced tomatoes packaging machine, This turnkey ORICS S-30 system is designed to minimize the number of human operators required for the packaging of diced tomatoes in 4 lb trays. Everything from the dicing of tomatoes to the placement in trays is fully automated, reducing the number of Operators from nearly a dozen to just 2 or 3. Featuring a Denester, Elevator Conveyor, Scale, Scale Interface, Heatseal and Outfeed, this system parallels the processing conveyors that utilize a screw infeed, an elevator conveyor, a dicer and washing/draining/transport system. This system represents a complete packaging system from start to finish and is just one example of how ORICS can increase your bottom line and streamline your applications.

Like all ORICS products, the S-30 is manufactured in the United States at our Farmingdale, NY facility. For more information call 718-461-8613
Orics cups and trays filling and sealing machines.

Cereal weigh fill and seal equipment.

The ORICS S-30 2up Tray sealing line for cereal; denests containers, accurately deposits cereal and seals at speeds up to 50-60 containers per minute. The specially designed Eco-Cut Film-Feed mechanism allows for maximum material and cost savings. This Film Mechanism also includes film registration for accurate placement of printed film. This additional feature allows for reduced material usage for point of sale retail purposes. ORICS fully integrates with scales and other third party suppliers to create complete lines. The ORICS S-30 is available in many configurations to meet a variety of production requirements. ORICS Machinery is made in the USA.
Orics cups and trays filling and sealing machines.
240 Smith Street, Farmingdale, NY 11735
718-461-8613

Orics full production line for Lasagna or Orics Lasagna tray packaging line, Product assembly to final packaging on the Orics ILTS-1200. Orics fully integrates with scales and other third party suppliers to create complete lines, lasagna tray sealing and packaging.

The series ILTS 1200 line can pack prepared dishes consisting of lasagna and cannelloni with a single production line. Designed and built with the maximum care to the cleaning and hygiene of every part,  with the following approximate hourly production, referring to the lasagna product:  1200, 1800, 2400 trays/hour with the “linear” type line installation. The number and arrangement of the dispensers depends on the recipe to specify the number of layers of pasta and sequence for dosing the liquid ingredients.

The Orics ILTS Modified Atmosphere Packaging (M.A.P.) Equipment is available in many configurations to meet a variety of production requirements. Orics Machinery is made in the USA. Visit our website at www.orics.com.
Orics cups and trays filling and sealing machines. Orics lasagna packaging line machines.
240 Smith Street, Farmingdale, NY 11735
718-461-8613

Orics SLTS-850

Watch Orics ILTS Complete Lasagna Tray packaging Machine.

1000 CMTS-LP