PHARMA MACHINERY & EQUIPMENTS: BY PIYUSH TRIPATHI

PHARMA MACHINERY & EQUIPMENTS: BY PIYUSH TRIPATHI

MANUFACTURING
Manufacturing is the use of machines, tools and labor to make things for use or sale. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale. Such finished goods may be used for manufacturing other, more complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell them to end users - the "consumers".

Manufacturing takes place under all types of economic systems. In a free market economy, manufacturing is usually directed toward the mass production of products for sale to consumers at a profit. In a collectivist economy, manufacturing is more frequently directed by the state to supply a centrally planned economy. In free market economies, manufacturing occurs under some degree of government regulation.

Modern manufacturing includes all intermediate processes required for the production and integration of a product's components. Some industries, such as semiconductor and steel manufacturers use the term fabrication instead. The manufacturing sector is closely connected with engineering and industrial design. Pharmaceutical machinery manufactures have understood the concept behind the process involvement for development of drug, machinery are developed as per client process requirement. Need for such development required in-depth study and monitoring process requirements of clients. Machinery manufactures updated their facilities by latest automated machinery for manufacturing parts, in addition to this there are also other visible trends that can explain committed interest of Indian machinery manufacturers further:
- Manufactures are going for CNC machine to get quality output
- Use of efficient and modern gadgets in the machine, like, VFD, PLC etc.
- Quality approvals and Trademarks, getting ISO approval and international certificate approval for quality manufacturing are also a part of dedication.
- To adapt and implement prototype machines are imported by manufactures.
- Tie-up & Collaboration for technology transfer with international manufactures.
- Expanding high tech facility to meet rising global demand.
Indian Pharma Machinery Manufacturers Association (IPMMA) is also established to work as entrepreneur’s team and also sets technological fairs and international and domestic meet providing a platform for B to B meets and bringing client and manufacture directly in touch with each other and working for mutual benefit.

PHARMACEUTICAL MACHINERY SEGMENT
Industrial segment specially pharmaceutical process and packaging sector have adopted modern means of process evolvement, manufactures have upgraded and adapted modern means of process plant development for providing controlled economical and efficient setups to cope up with the up coming trend and technological advancements. In many production plants, pharmaceutical manufacturers have developed a high degree of automation. Milling and micronizing machines, which pulverize substances into extremely fine particles, are used to reduce bulk chemicals to the required size. These finished chemicals are combined and processed further in mixing machines. The mixed ingredients may then be mechanically capsulated, pressed into tablets, or made into solutions. One type of machine, for example, automatically fills, seals, and stamps capsules. Other machines fill bottles with capsules, tablets, or liquids, and seal, label, and package the bottles.


At the time of industrialization growth flow in 60’s and 70’s the pharmaceutical industry big or small were forced to imported machines from Europe for their processing and packaging needs. During the phase entrepreneurs, engineers in India realized the need for development in the sector for better improvement and meeting requirements of the fastest growing Industry Pharmaceutical process and packing. After the declaration of industrial policies in the mid 70's Indian government introduced very high import duties and restrictive import licensing policies. This resulted in a spark in the Indian engineers to prove their excellence as enterprises to manufacture machines locally. Engineers had the skills and now the support of industry and associations were form to cater the domestic market for better improvement as perhaps the only route for the pharmaceutical industry to enhance production and cater to the growing demands of the domestic market.

With this big a size of the industry a proper setup development plan and skill to cater the need was inevitable. Pharmaceutical Industry grew at the most fastest rate in India for its mineral rich resources, ore availability, raw material power house of such basic ingredients which were cheaply available in local market strengthen the growth. To support the industry Pharmaceutical Machinery Manufactures also upgraded themselves and adapted to a marketing plan. To ensure proper flow and meeting technological upgrades manufactures had to plan a proper strategy for not only meeting requirements but also giving technological upgrade the equipments for faster and efficient working.

DOMESTIC MANUFACTURING CHALLENGES
The machinery manufacturing industry, like all international manufacturers, continues to evolve. Domestic and foreign competition has required the industry to adopt new technologies and techniques to lower costs and raise the productivity of its workforce. For example, using high-technology production techniques, including robots, computers, and programmable equipment results in productivity gains and helps to maximize the use of available equipment and workers. Increasing technology and automation also reduces the number of unskilled workers needed in the production process.

Pressures to reduce costs and maximize profits have also caused manufacturers in the industry to adopt new business practices. One example is the practice of contracting out support functions, such as janitorial and security jobs, and increasingly some administrative services and warehouse and shipping jobs. Rather than employ workers directly for these jobs, a manufacturer will often contract with another company that specializes in providing these services. This practice reduces costs by forcing service providers to compete for the work, allows manufacturers to focus on their core design and production activities, and increases manufacturers’ flexibility by letting them add and subtract contract workers more easily than they could hire and fire employees.
These changes have had a profound effect on the machinery manufacturing workforce. By automating many of the production processes and outsourcing many of the administrative and support functions, it has reduced the need for many less skilled workers and increased the skill level required for the remaining workers. These changes are allowing the industry to remain competitive and meet the demand for machinery that other industries rely on.

One of the greater challenge faced is specialization in restricted field of work to set up a work force which requires, Engineers specialize in a particular facet of design. Mechanical engineers design the moving parts of the machine, such as the gears, levers, and pistons in engine and hydraulic systems. They also direct the work of mechanical engineering technicians, who run tests on materials and parts before they are assembled into the final product. For machines with complicated electric or electronic systems, electrical and electronics engineers also assist in the design and testing process. Industrial engineers determine how best to allocate the resources of the factory—both workers and equipment—for optimal production. Once a design is finished and simulation testing complete, mechanical drafters creates the plans that production workers use in the assembly of the machine. They provide specifications and diagrams for each part required, as well as assembly instructions for the final product. Computer control programmers and operators manage the automatic metalworking machines that can mass produce individual parts. They also write programs based upon the specifications of the part that defines what operation the machine should perform. Machinists produce precision parts that require particular skill or that are needed in quantities too small to require the use of automated machinery. Welding, soldering, and brazing workers operate machines that join two or more pieces of metal together; they may also weld manually as well.

Once all of the parts have been made, it is the responsibility of assemblers and fabricators to put them all together to finish the product. Some assemblers specialize in one particular stage of the process, while others, such as team assemblers, work as a group and may contribute to an entire subassembly process. While there has been increased automation of the assembly process, many parts of the products still have to be put together and fastened by hand. When assembly is complete, painting workers apply paint or a protective coating to the exterior of the machine.

While quality control is a responsibility of all production workers, it is the primary focus of inspectors, testers, samplers, and weighers. These workers monitor the entire production stage, making sure that individual parts, as well as the finished product, meet the standards set by the company.

In addition to production-specific occupations, this industry has various managers and administrative support personnel to handle functions such as human relations, accounting, and general management. The sales function for many companies is increasingly important. Sales representatives and sales engineers often work together to market the company’s machines to potential buyers, demonstrating how the machine may reduce costs or increase sales. They also explain how to operate the machine and answer buyer’s questions. Sales engineers in particular use their technical background to advise clients on how the machine can best be applied in their individual circumstances and to suggest custom designs or modifications to the equipment as needed.

MANAGEMENT ASPECT OF MANUFACTURING
The main factor affecting the level of employment in the machinery manufacturing industry is the high rate of productivity growth. Increases in productivity allow companies to produce more goods with the same number of workers. Even though output in machinery manufacturing is expected to increase significantly, firms are capable to meet the increase through higher productivity of existing workers, rather than by creating new jobs and increasing work force.

A second factor expected to cause some employment declines in machinery manufacturing is the growing number of imported parts. Earlier only raw material was available now finish part machined and finished are also available and raw material suppliers are supplying the same to compete with the competition. This industry is less likely to lose a large part of its output to imports from other countries than some other manufacturing industries. The large size and complexity of many of the types of machinery made by this industry and the relatively skilled workforce it requires is an advantage that many manufacturing industries do not share.

The manufacturing focus in the early-to-mid-2000s was on new and diverse products to meet the individual needs and desires of the market. Companies in 2003 wanted "quick changeover capabilities, flexibility, and fast speeds" more than any other features. Consequently, the industry was expecting continued growth to meet demands for newer and better packaging machinery, replacing older equipment with newer, faster, more efficient, and more automated machines. Trends toward lightweight, individually designed, flexible, and reusable packaging increased demand for the design of machines that could manufacture such packaging.

Demand for machinery is expected to remain strong. Machinery is important for all industries because it boosts their productivity, and advances in technology will make machinery even more efficient and thus more desirable. Demand for machinery is highly sensitive to cyclical swings in the economy, however, causing employment in machinery manufacturing to fluctuate. During periods of economic prosperity, companies invest in new equipment, such as machinery, in order to boost production. When economic growth slows, however, many companies are reluctant to purchase new machinery. These changes in demand cause machinery manufacturers to replace fewer workers who leave or even lay off some workers.

Although overall employment in the machinery manufacturing industry is expected to decline, the outlook for occupations will vary; some will experience larger declines than others, while some will even experience growth instead. Increased automation and more efficient production processes will cause employment declines in assembler and fabricator occupations. Office and administrative support workers will also experience declines as a result of increased automation and contracting out. Employment in professional and management occupations will experience smaller declines relative to other occupations in the industry; engineers in particular will experience very good employment opportunities, as they are responsible for increasing innovation and competitiveness in the industry.

USE OF PROCESS & PACKAGING MACHINERY
Primary use of process and packaging machinery is to elated equipment and it's uses.
BLENDING & MIXING
Blending is to combine or mix so that the constituent parts are indistinguishable from one another and to obtain a mixture of particular character, quality or consistency. Blending machines such as Agitators, Conical blenders, Continuous mixers, Dough mixers, Emulsifiers, Gas, Homogenizers, In line mixers, Meat mixers, Paste mixers, Plough blade, Powder mixers, Ribbon mixers, Solid phase mixers, Viscous product mixers, Z Blade mixers.
GRANULATORS
Current good manufacturing practices increasingly require that product is fully contained during processing to protect operators and environment. Integrated process systems not only offer containment but improved productivity through automation, increased yield and efficient cleaning procedures. The granulation process can be one of the following; Low shear dry granulation, high shear wet granulation and melt granulating. Mixing and granulating can be combined into one machine.
HOMOGENIZERS
Homogenizer is to reduce to particles and disperse throughout a fluid. Inline homogenizers are the ideal solution for continuous processing of emulsions and dispersions.
MILLING & SIEVING
The integration of all types of mills and sieves can be tailored to suit the individual needs. There can be specific applications such as hoist mounted systems and high powder containment levels. Other design options include nitrogen purge systems and CIP systems. Quick change over between products is essential and the application of integrated control systems is needed. There are various types of mills such as toothed colloid, corundum stone and perforated disc mills. Product is loaded via a hopper that can also be fitted with a feed screw, or via a pump. The milling zone is sealed by a single or double-acting mechanical seal, with no dead space. All product contact surfaces should be very easily cleaned with no need for dismantling (CIP). Thorough washing of all static seals during the cleaning process complies with the hygiene standards. In all industrial sectors, demands in terms of flexibility and hygiene management are constantly on the increase.
POWDER HANDLING
Common problems include material blockages where sticky poor flowing materials will not discharge from an IBC. Segregation of blended material is another common problem. Segregation can be caused during the discharge from the IBC. It can also occur after discharge from the IBC when product is allowed to fall through long chutes in free fall, and displaced air from below is forced back up the chute and separates the finer particles from the coarser particles.
PROCESS VESSELS
Processing vessels need to be of a high quality construction and are widely used by the food and processing industries. A selection of sizes, specifications and agitator combinations are available to suit most needs. Stainless steel is used for all fabricated parts to meet industry requirements. Pressurized jackets for heating by steam or water facilitate boiling, cooking, melting, dispersion and mixing of products. Vessels can also be equipped for oil heating or water cooling.
IBC / INDUSTRIAL BULK CONTAINER
Container blending has long been established as the most efficient method of blending granules and powders in the pharmaceutical manufacturing process. Reduced loading and unloading times, reduced cleaning time of both machinery and room, improved containment and batch integrity have established IBC blending as the pharmaceutical industry’s technology of choice.
PROCESS PUMPS
Various types of process pumps can be used depending upon the type of product to be moved between or within the complete process line of the various integrated sub systems. Pumps such as centrifugal, diaphragm, dosing, gear, metering, reciprocation and vacuum can be used. For example, vacuum pumps will be used for powder handling but screw metering drives can be used for more accurate powder movement.
PROCESS CLEANING MACHINES
The cleaning of the process machines will be mainly carried out by CIP (Clean In Place) systems. Depending on the sensitivity of the product being produced, the equipment may be cleaned aseptically and therefore eliminating any possible contamination from outside.
STERILIZING MACHINES
Sterilizing machines can also be called, Autoclaves and Retorts. There three main types of sterilizing system; static, rotary and pilot or laboratory systems.
GENERAL CHARACTERISTICS ARE:-
• Steam-Water sprays mix.
• Top shower for cans and glass jars plus side shower for pouches and trays
• Indirect cooling system by heat exchanger allows water recovery.
• All vessel, pipe work and valves and heat exchanger in stainless steel materials
• Insulated shell with mirror polished stainless steel cladding
• PLC control with modem connection allows remote troubleshooting and servicing
• Process monitoring in the operator interface with complete information of temperature, pressure, time and flow
• Easy product recipe setup with password protected access
• Optimum heat distribution (+/-0,5 ºC)
• Accurate pressure control (+/- 0,05 bar)
The rotary machines will use inverter drives for accurate control during the sterilizing process. There is also associated equipment such as basket trolleys and automatic loading systems available to fully automate the sterilizing process of product.
PROCESS CONTROL SYSTEMS
Compliance, traceability, consistency, and reliability of measurement data are primary concerns for the pharmaceutical industry. The control system is needed to verify the product quality through measuring, counting, inspection and testing of the manufacturing process. Operator input data; scanning systems and feedback systems are used.

PROCESS AND PACKAGING MACHINERY IN GENERAL
These machine types are very general indeed. Each area or sector of packaging equipment can be expanded upon to reveal the various applications that are available today. As technology advances, packaging machines are becoming more and more advanced to not only meet the current demands but to try and "future proof" the packaging equipment and product development within an organization. This can have a bearing on machine costs plus the interchangeability of operators and training. Packaging machines can be integrated into an existing line to enhance the production output or to reduce the labor and down type to pack the product. From single machine, to small systems or complete lines containing more than one new or existing / reconditioned packaging machine can be installed. Depending on the size of the installation, project process line and packaging machinery are available domestically to withstand & compete with market requirements.


Article by:
Piyush Tripathi
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