Rebuild Process 

  Pharmaworks Rebuild Component Upgrades

 blister_rebuild_frame The machine is completely disassembled to the frame. The frame may have modules added (340 mm each) to the machine or may have modules removed to create the correct layout for the application.
 rebuild frame repaint The frame is then stripped and repainted.
 mechanical rebuild before This is a single station before being rebuilt.  All stations are sent to our dedicated rebuild department for a complete tear down and complete rebuild including all bearings, all bushings as well as any other wear parts. All other (non wear or non moving) station components are stripped and recoated or repainted.  See below for the result.
 mechanical rebuild after This is the same station as above after being rebuilt by Pharmaworks.
 Inspection Inspection:
Each component inspected and tagged for reconditioning or replacement
 Documentation
Documenting:
All assemblies properly documented. At the end of the project, a complete BOM exists with all of the replaced components recorded.
 GMP area sloped covers This shows upgraded GMP guarding on a rebuild.  Pharmaworks is committed to not only improving machine performance but also to improving GMP aspects of the machine.  When executing a full rebuild, we replace the covers with sloped stainless steel covers (rear of machine) and we also replace top and front covers with stainless steel covers. This reduces costs due to reduced cleaning time
 UPS4 heater station This is a UPS4 Heater station with Pharmaworks heater plates.  Our six zone cartridge heating dramatically reduces cost of heater plate replacement when a zone fails. When an RTD or heater cartridge is determined to be faulted, the component can be replaced  without loss of the entire plate. Further, with the split plate design, the contact surface can be replaced without loss of the entire plate. This saves time and reduces maintenance costs.
 ET rotary servo indexing The ET indexer follows the main drive motor (requires servo main drive option). The result is very smooth indexing, since there is no dependency on mechanical shafts. In the existing configuration, as the line shaft wears and develops “rippling,” the indexer starts to also show this effect. Using the servo upgrade, this is eliminated completely.

Allows print registration to be accomplished by adjusting the index move and eliminates mechanical adjustments. The index length is entered from the HMI and stored as part of the recipe.

A change-over only requires either recipe recall or a new index length to be entered.
 MT indexer laser feedback Servo MT indexer using laser feedback, allowing the MT index to be corrected each cycle, ensuring accurately punched blisters.  Index length is entered from the HMI. This servo  indexer is less complicated than the existing MT indexer and is much smoother. Significant savings are achieved in change-over time.
 ET MT drive motors servo This upgrade involves removing the existing AC motor driving the line shaft. It is replaced by two servo motors. One servo motor drives the ET portion of the machine. The other motor drives the MT portion of the machine. This allows ratio  changes to be done from the HMI rather than by mechanical means. The machine cams are also generated from each motor. This upgrade eliminates risk of machine being out of time (tooth skipped on chain/sprocket) during mechanical change-overs.
 rebuild loop encoder The loop encoder upgrade allows the precise monitoring of the MT loop by the PLC. Different format loop settings are stored and recalled allowing consistent monitoring.  This reduces risk that reject blister is accepted.
 Rebuild pneumatic system A new pneumatic package replaces the existing package. This includes all fittings, hoses, valves etc. The cooling package is completely replaced as well. This reduces spare parts inventory, due to parts being readily available locally
 UPS4 Seal Pressure Monitoring Real-time pressure monitoring at the seal station reduces risk of improperly sealed blisters.
 UPS4 Reject System  
The high speed reject system with positive reject verification means fewer reject problems, reducing unnecessary machine stops.
 UPS4 Cooling Monitoring Cooling monitoring is upgraded. Flow monitoring ensures that cooling liquid is flowing properly. PLC monitoring of exhausting water flow using flow sensor will shut down all heating if flow is severely reduced or stopped due to a failed coolant line or a blockage.
 UPS4 Seal Overheating Monitoring PLC monitors seal station over-temperature due to insufficient cooling. This feature saves costs of replacing the bearings and other critical components from premature failure, reducing downtime.
 UPS4 Base Material Loop Control Upgrade on UPS4 base material loop control includes removing the mechanical pendulum control of the base material. Using sensor technology, the base material is held in a loop and the sensor maintains the loop. Using this method allows gentle and consistent uwinding of material. It eliminates the need for material brakes (cold form) and reduces drag on the web prior to the heater station (thermoform).
 UPS300 Servo Upgrade  UPS300 Servo Upgrade
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