Smart PCA40

The all-in-one Print&Check and aggregation workstation

Semiautomatic workstation for Serialization and Aggregation 

Smart PCA40 is a semiautomatic machine with an integrated vision system capable of managing both cartons serialization and cartons-to-case aggregation up to pallet level.

This compact solution is the ideal choice for companies that need to serialize and aggregate cartons of different dimensions to cases even production areas with limited spaces. Thanks to its compact and ergonomic structure, Smart PCA40 can be easily moved in different areas of the production site.

This flexible solution allow to comply very quickly with the upcoming regulatories: it grants that the working cycles are executed in a safe way and that they are fully compliant to the requirements of pharmaceutical industry.

The system can process not serialized products, PODA, PODA+, cartons-case and cartons-case-pallet aggregation. Moreover, during aggregation processes, possible partial case/pallet can be managed.

TECHNICAL INFO

Sizes serialization module 1550x895x1785 mm (L x W x H)
Sizes aggregation module Custom
Power Supply 230 V monophase 50hz + EP
Consumption 1,1 KW
Expected absorption  5A (complete with monitor, ink-jet and cameras)
Max mechanical speed   up to 120 cartons/min (depending on different factors)
Cartons Sizes  Min: 30x50x15 mm (L x W x H)

Max per 200mm: 400x200x200mm (L x W x H)
Max per 400 mm: 400x200x200mm (L x W x H)

Supported weight for carton  Up to 3 kg
Case sizes Min: 200x120x120 mm (L x W x H)

Max: 600x400x400mm (L x W x H)

Why Smart PCA40 is the perfect choice? Read below.
Easy to use. The intuitive and user friendly interface guides the operator during the whole work cycle 
Practical. The handy structure facilitates the machine handling 
 
Functionality and reduced dimensions. Quiet, fast and suitable even in medium-small production spaces
 
Efficiency. Low maintenance required and easy cleaning
An all-in-one solution: serialization, aggregation and reworking operations
GMP (Good Manufacturing Practices) guidelines compliant

SEA Vision software features

  • Printing and checking of codes on cartons/cases/pallet
  • ANSI Grading control on cartons and case labels codes
  • Partial management of case and pallet
  • Real time images
  • Multi level aggregation
  • Custom reports generation
  • Automation provided by SVM integrated tool
  • CFR 21 part 11 compliant

Hardware features

  • Integrated HMI touch-screen display
  • In-Line printer for serialized and variable data printing
  • Cameras for carton’s code reading
  • Scanner for in-batch reworking operations
  • Scanner for pallet aggregation (provided just together with the aggregation module)

Workstation features

  • Side presence of Ethernet points to connect the machine with network infrastructure
  • Adjustable chain for an easy positioning of the aggregation module close to Smart PCA40 serialization unit
  • Adjustable product guide on operator side movable with parallelogram safety system
  • HMI 45° rotation both right and left side
  • Side camera horizontal regulation

SYSTEM TECHNICAL INFORMATION:

The heart of Smart PCA40 is SEA VIsion software: the renowned vision system capable of perform many types of inspection in a completely trusty way, ensuring a very easy set-up of controls and allowing the products to be fully serialized and thus compliant to the Track&Trace regulations worldwide.

Created as an instrument to recognize optical characters the software is integrated with the machine and it is capable to perform a huge number of different controls with the highest flexibility.

The system configuration is modular and scalable: new functions can be added over time and every control is associated to a specific licence.

Furthermore, its versatility allows to create tailor-made solutions for every kind of inspection requirement.

THE AUTOMATION KEY: SEA Vision Machine (SVM)

It is a module available upon licence, that by means of configurable steps, allows to communicate with the different systems of which the machine is composed in order to manage specific processes of automation.

Composed by a set of instructions customized for the productive need, SEA Vision Machine manages all the automation phases communicating with the user in a simple way. This phase is managed during the batch start providing, automatically or manually, the necessary and specific information for the whole process.

Smart PCA40 takes advantage of this architecture of automation to manage the complete process and the handling of the machine, even without PLC.

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Working Cycle description
1. CARTONS INSERTION AND PRINT
2. CONTROL AND ANSI GRADING
4. REJECTION MANAGEMNT 
5. PRINTI AND CHECK OF CASE LABEL
6. CARTONS POSITIONING IN CASE AND AUTOMATIC AGGREGATION CARTONS-CASE
7. CASE-PALLET AGGREGATION

Description of serialization work cycle

Smart PCA40 allows to print and check pharmaceutical cartons.

1. CARTONS INSPECTION AND PRINT

The carton is manually fed on the conveyor belt; the codes can be printed on the side carton flap (or optionally on the top side).

2. Inspection and ANSI Grading 

The camera, positioned as standard on opposite operator side, perform the codes insepction and the ANSI Grading control.

4.  Gestione Scarto   

The light indicator shows the inspected item status. If the result is positive, the carton goes on; if there’s an error the indicator becomes red, giving the operator an input for manually removing the product, thus granting a 100% safe work cycle in compliance with procedures. When the bad carton is removed, the conveyor belt automatically restarts, going on with the normal process.

Description of the cartons-case-pallet aggregation work cycle

Smart PCA40 thanks to availability of a dedicated optional module, can perform multilevel aggregation operations.

5. Print and check of case labels

A label is printed by the system, so that the operator can apply it manually to the case. Once the case is positioned on the aggregation station, the label codes are inspected by the side-cameras.

6. Cartons positioning inside case and aggregation cartons-case

The inspected cartons are placed manually inside the empty case (on the aggregation module). The case is removed from the aggregation module and the automatic aggregation occurs.

8. Aggregation case-pallet

The last step consists in aggregating cases to pallet, printing automatically the pallet label. The label is then checked through the manual scanner.