As cases of COVID-19 began to intensify across the U.S., a diagnostics manufacturer reached out to ESS Technologies to build two identical filling systems with automated cap torque for diagnostics vials to be used in manufacturing COVID-19 test kits. Speed and urgency drove the project, which required the system to fill up to 120 vials/min.
Though originally developed for vials used in COVID testing, the machines can be used for pharmaceutical manufacturing applications using vials or small bottles. Available in semi-automatic and fully automated configurations, ESS’ flexible filler/capper uses a circular puck conveyor system to transport vials or small bottles to the inline filling system. A timing screw drive positions six vials beneath the six-up diving nozzle assembly where a precise amount of diagnostic reagent is dispensed. The cap placement is automated using FANUC’s SR-6iA SCARA robots and a cap feeder. A three-up final torque station then applies the precise amount of torque to the caps. The machine uses Allen Bradley PLC controls and a 6 in. color touchscreen HMI for ease of operation. An optional 10 in. HMI is available. The system provides fast changeover - under 10 minutes.
In addition to filling and capping COVID test kits, a second diagnostics manufacturer has asked ESS to build several end-of-line packaging systems comprised of 13 robots for collation, cartoning and case packing sterile test kits. ESS has been able to offer fast delivery times for these systems, allowing the manufacturers to ramp up their important production capacity. According to Kevin Browne, president and founder of ESS Technologies, Inc. “Everyone at ESS immediately understood the urgency of building high speed, high performance packaging machinery to increase the manufacture of test kits and prepare for future vaccine packaging. As a critical manufacturer for the pharmaceutical and diagnostics industries, ESS worked with suppliers to keep the supply chain flowing, and we were able to deliver two complete systems in just a few weeks.”
For more information on ESS Technologies visit: www.esstechnologies.com.