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Product development makes demands on manufacturing. We are used to demands. With a large proportion of our machinery building being custom made machinery our large engineering team are able to draw on core competencies to build a custom machine to assembly, convert of pack your product.
Managing risk can be a tricky business. Project management is vital to the success of a customised machinery project. From the outset the project need to be clearly defined in the form of a User Requirement Specification (URS). Often we carry out Proof of Principal Trials (PoP) or a design Study to evaluate the different options available. After successful PoPs we put together a Functional design specification (FDS). It is on the basis of an FDS, agreed with the customer that the serious designing and machining can begin. Having proved initial concepts and agreed the design the project has got off to a positive start. Upon completion of the assembly of the customised machinery we carry out a Factory Acceptance Test. The FAT is an evaluation of the equipment by the customer against the original URS. Assuming successful FAT the machine leaves our factory and ownership transfers to the customer.
Example 1: Inhaler Assembly
The task was to dose 200 mg of powder into a chamber inhaler. Dose accuracy was critical to the project. We designed custom made machinery that lifted the inhalers out of trays, onto a transport system. Consequently the powder was dosed, the powder chamber capped and the inhalers returned to their trays.
Example 2: Unit dose pouch with foam applicator
The Del pouch was designed as a cream unit dose. The small foil pouch can be squeezed to release cream into a circular foam pad from with it can be applied to the body. Drawing on our experience with sachet machines we provided custom made machinery that die cut 4 pouches simultaneously, dosed cream and applied a foam pad to the opening. A press seal then separated the cream from the foam.
Example 3: Applying of Rubber seals onto Aluminium cans for metered dose inhalers
The task was to design a tailored machine to apply a single seal to the neck of a aluminium can at 500 cans per minute. The seal had to sit in exactly the right place on the neck. The assembled cans had to be counted into a box. A camera system inspected the positioning of the seals and the machine ejected both rejects and cans for In process controls (IPC). Out expertise in continuous motion assembly allowed us to provide a solution that was customised to the specific requirement of the project, achieving the required output.
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