Tablets Packaging Machines are of great significance in the pharmaceutical packaging process. However, the occurrence of faults can disrupt production and affect product quality. The following presents preventive measures against common faults to ensure the smooth and reliable operation of these machines.
I. Prevention of Abnormal Conveyance of Packaging Films
1. Regular Cleaning and Inspection of Conveying Rollers
Set up a strict cleaning routine. After each operation or at specific intervals (such as after every shift), use appropriate cleaning tools and agents to clean the conveying rollers, eliminating any adhered drug residues, dirt, or impurities.
Frequently check the surface state of the rollers, including wear levels and flatness. If slight wear is identified, take measures like grinding for restoration. In case of severe wear, replace the rollers without delay.
2. Motor Maintenance and Monitoring
Comply with the maintenance instructions provided by the manufacturer. Regularly clean the motor casing, ensure the proper functioning of the cooling fan, and replace the lubricant as scheduled.
Install a motor monitoring system to keep a close eye on parameters such as current, voltage, and rotational speed. Once any abnormality is detected, immediately stop the Tablets Packaging Machines for inspection to prevent further damage.
3. Calibration and Inspection of the Tension Control System
During the installation and commissioning of the machine, ensure the accurate calibration of the tension sensor and controller. Conduct regular recalibrations, usually every 3 - 6 months or when the packaging film type changes.
Before starting the Tablets Packaging Machines each time, check the connection status of all components in the tension control system and look for any signs of sensor damage or loose connections.
II. Prevention of Poor Heat Sealing
1. Optimization of Heat Sealing Parameter Settings
According to the characteristics of the packaging film (material, thickness, etc.) and the capabilities of the Tablets Packaging Machines, create a detailed parameter table for heat sealing temperature and time. When changing the packaging film, strictly adjust the parameters accordingly.
For new packaging film materials, perform small-scale heat sealing tests prior to formal production. By observing the sealing quality and testing the airtightness, determine the most suitable heat sealing parameters.
2. Mold Maintenance and Cleaning
After each use, use dedicated mold cleaning tools to thoroughly clean the heat sealing mold, removing any packaging film fragments, oil stains, or other contaminants. Periodically, conduct a more comprehensive cleaning with appropriate chemical cleaners, taking care not to damage the mold surface.
Regularly inspect the mold for wear. If wear is detected, repair or replace the mold promptly. Also, ensure the correct installation of the mold to ensure uniform heat sealing pressure.
III. Prevention of Inaccurate Measurement
1. Regular Calibration and Maintenance of the Measuring Device
Frequently check the measuring device for wear and replace any worn parts in a timely manner. For hoppers that are prone to clogging, install effective filtering devices to prevent foreign objects from entering and affecting measurement accuracy.
2. Reduction of Equipment Vibration
Ensure the Tablets Packaging Machines are installed on a stable and level foundation. Use shock-absorbing pads or other vibration reduction equipment to minimize vibration during operation. Regularly check and tighten any loose installation bolts.
Conduct balance checks and maintenance on the internal transmission parts of the machine. For example, perform dynamic balance corrections on rotating shafts and replace severely worn transmission parts to reduce vibration caused by component imbalance.
3. Attention to Changes in Material Characteristics
Whenever there is a change in the characteristics of the tablets (shape, size, weight, etc.), immediately adjust the parameters of the measuring device. Keep a detailed record of all material characteristic changes and the corresponding adjustments made to the measuring device.
For new tablet varieties, conduct extensive pre-production tests to evaluate their impact on measurement accuracy and adjust the measurement strategy accordingly.
IV. Prevention of Excessive Noise during Machine Operation
1. Maintenance of Mechanical Transmission Parts
Follow the recommended lubrication schedule for mechanical transmission parts such as gears, chains, and bearings. This helps maintain proper lubrication, reducing friction and noise generation.
Regularly check the wear and tear of these parts and replace any that exceed the allowable wear limit. When installing new parts, ensure proper alignment and fitting to avoid additional noise.
2. Normal Maintenance and Inspection of the Motor
Keep the motor clean by regularly removing dust and debris from its surface. Inspect the fan blades for damage or looseness and repair or replace as necessary.
Conduct routine performance tests on the motor, including insulation resistance measurements and checks of starting and running currents, to ensure its proper operation and minimize noise due to motor faults.
3. Prevention of Foreign Objects Entering the Machine
Install protective shields around the Tablets Packaging Machines to prevent small tools, parts, or other foreign objects from entering. Additionally, screen and clean the incoming packaging materials to avoid debris from entering critical machine areas.
Regularly inspect the integrity of the protective shields and repair any damage promptly. If abnormal noises are heard during operation and foreign object entry is suspected, immediately stop the machine for inspection.
V. Prevention of Control System Faults
1. Protection and Maintenance of Electrical Components
Equip the Tablets Packaging Machines with a stable power supply system, including voltage stabilizers and over-current protection devices to protect electrical components from voltage fluctuations and excessive current.
Regularly inspect the condition of electrical components such as controllers, drivers, and sensors. Look for signs of damage or loose connections and replace components as per the manufacturer's recommended schedule to prevent failures due to aging.
2. Inspection and Maintenance of Wiring Connections
Routinely check the wiring connections, including wires, plugs, and sockets, to ensure they are secure and free from loose, broken, open, or short-circuit conditions. For connections vulnerable to vibration, use additional securing measures like wire clips or cable ties.
After any equipment repair or relocation, carefully verify that all wiring connections are properly restored. Keep the connection areas clean to prevent dust and oil from affecting electrical performance.
3. Maintenance and Update of the Software System
Install reliable anti-virus software and conduct regular virus scans and removals on the control system software to prevent failures due to virus infections. Also, perform regular backups of the software data to avoid loss.
Stay informed about software updates released by the manufacturer and apply them promptly. After an update, conduct thorough testing to ensure the Tablets Packaging Machines operate normally.
