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Turning used into new

> Bosch Packaging Services modernizes coater for Takeda Brazil


In order to keep up with fast developing technical standards, pharmaceutical manufacturers face the question whether investing in new equipment is the most profitable solution. Instead of purchasing completely new machines, in many cases a modernization is worth considering – especially when the existing equipment still shows good overall performance and modernization work can be carried out with minimum downtime. Following more than ten years of successful production on the tablet coater, the pharmaceutical manufacturer Takeda Brazil decided that it was time for an upgrade. After the service technicians from Bosch Packaging Services had exchanged the control system and spray guns, the coater was as good as new again.

State-of-the-art equipment is one of the most important prerequisites for a successful pharmaceutical production – not only in terms of high safety standards, but also for fast and easy handling, as well as reduced downtimes. This is also true for the globally operating drug manufacturer Takeda. Founded more than 230 years ago in Japan, the company’s portfolio now comprises more than 700 products that are sold in 70 countries. After the acquisition of the pharmaceutical company Nycomed in 2011, Takeda took over operation at the Brazilian plant, located in the city of Jaguariúna in the State of São Paulo. It is one of the most modern facilities in Latin America, equipped to produce solid, liquid and semi-solid pharmaceuticals. Takeda supplies the Brazilian market with medication for the treatment of allergies and gastroenteritis, as well as immunological and respiratory diseases.

Technical upgrade in a short time-frame

When Takeda started operating in Brazil, the company took over a Premier Coater 500, manufactured by the Bosch product brand Manesty. The machine is able to handle large batches up to 600 liters. Capable of working with aqueous and organic coating and sugar solutions, the machine is suited for all solid dosage forms including tablets in different sizes, as well as soft and hard capsules. Takeda uses the coater to produce Dramin, a drug against nausea, and Venalot, a medicine for vascular diseases, among other products. After more than ten years of production, the control system no longer met the latest technical standards Takeda needed for its high-quality products. The spray guns also had to be exchanged. “The coater is crucial for our production,” says Luis Lopes, maintenance supervisor at Takeda Brazil. Since the company did not want to risk any unplanned downtime in the near future, the engineering team of Takeda had to take a decision.

“We were always very satisfied with the performance of the Manesty Premier Coater 500. So we decided to give it a technical upgrade instead of replacing it,” Luis Lopes explains. “Therefore it was only logical to contact our supplier Bosch for assistance.” The technical team of Bosch Packaging Services in Brazil developed a tight project plan to implement the upgrades without losing too much valuable production time during the installation process. Service engineers from the Bosch brand Manesty in Knowsley, UK, and local Bosch engineers established a project team on site. The joint expertise, as well as the dedication of the team members, was key to a successful modernization of the coater. The technicians even continued their work on site despite public holidays and managed to reduce the intended time-frame of six to only four weeks.

Easy operations and more time for production

The modernization project for Takeda Brazil consisted of two major parts: the upgrade of the obsolete control system and the replacement of the worn spray guns, as well as the electrical cabinet Flowtab. The technicians changed the entire control technology of the coater to the new m-tec control system. With its intuitive operator interface, it enables the pharmaceutical developmers of Takeda, the maintenance technicians and production operators to precisely control all critical coating process parameters, including air handling, application of the coating solution and cleaning operations. Data capturing and reporting options allow accurate recording of all processes. “We are now able to trace all parameters and production steps. This makes our work a lot easier,” Luis Lopes explains. All process steps can be individually configured, programmed and recalled to develop reliable multi-stage recipes.

Additionally, the Manesty Premier Coater 500 was equipped with new OptiCoat spray guns. Due to their special geometry, the new spray guns achieve an especially good droplet spray distribution, and minimize air flow turbulences. Moreover, the nozzles with anti-bearding technology reduce spray gun blockages. “Besides all the technical details, the new spray guns require less maintenance, which results in a significant reduction of downtime for cleaning,” Luis Lopes explains. “This gives us valuable extra time for production.”

Training sessions for improved coating results

After a successful revalidation of the Manesty Premier Coater 500, Takeda was ready to take up production again. During the last week of the implementation process, the Bosch service technicians provided comprehensive process training for the operating and technical staff of Takeda Brazil. The sessions not only comprised the handling of the new control system. They also covered general questions about the coating process, for instance how to improve the overall coating quality of different solid dosage forms.

“The support from Bosch was very good. The same accounts for the commitment of every member of the team,” Luis Lopes says. “Whenever additional questions arose, for example regarding spare parts management, project manager Oscar Flint and his service team of local technicians and Manesty service engineers from the UK were there to help with all technical information in next to no time.” Bosch also took care of the whole project management including all the legal issues for working permissions of foreign engineers. “Getting a working visa can sometimes be quite challenging in Brazil. We were very thankful that Bosch took care of all the paper work,” Luis Lopes adds. “In a nutshell, we received highest quality on all levels.”


 

New local service support based in Brazil
To ensure quality in the long run, Bosch Packaging Services has expanded its after-sales services support in Latin America. Since March 2015, a newly established regional service hub has taken up operations in São Paulo. Bosch has a base of approximately 3,000 machines installed in the Latin American market. By establishing an independent regional hub for the whole Latin American market, Bosch is able to offer customers one single point of contact for all service enquiries. The new service team consists of 23 employees and is responsible for all Latin American countries south of Panama.

Contact:

Oscar Flint
Project Manager
Bosch Packaging Services
Oscar.Flint@bosch.com
Tel. +55 11 2117 6881

About Bosch Packaging Services

Bosch Packaging Services develops and provides after sales services for packaging machines. The product portfolio ranges from standard services, such as spare parts, modernizations and service technicians that increase availability to complete plant efficiency audits and Overall Equipment Effectiveness (OEE) enhancing services. A worldwide network guarantees Bosch is a local service partner. For more information, please visit www.boschpackaging.com.

About Bosch Packaging Technology

Based in Waiblingen near Stuttgart, Germany, and employing 5,600 associates, the Bosch Packaging Technology division is one of the leading suppliers of process and packaging technology. At over 30 locations in more than 15 countries worldwide, a highly-qualified workforce develops and produces complete solutions for the pharmaceuticals, food, and confectionery industries. These solutions are complemented by a comprehensive after-sales service portfolio. A global service and sales network provides customers with local points of contact. Additional information is available online at www.boschpackaging.com.

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