Nutraceutical Manufacturing
I nutraceutici, o integratori alimentari, appartengono a un settore dinamico che affronta diverse sfide. Questi prodotti possono variare da compresse e capsule a polveri e persino gomme da masticare. I produttori spesso devono utilizzare attrezzature di grado alimentare nelle loro linee di produzione e seguire i protocolli cGMP. In ogni caso, i materiali solidi utilizzati possono essere facilmente movimentati con il giusto conveyor a vuoto Piab.
Sistemi per la Produzione di Nutraceutici di Piab
Ecco come i sistemi di trasporto Piab garantiscono una produzione efficiente di nutraceutici e integratori alimentari.
Prelievo di materiali solidi da barili, IBC, sacchi o big bag
La produzione di nutraceutici inizia con il carico degli ingredienti nel processo con il metodo giusto. Piab offre una vasta gamma di accessori, tra cui lance di alimentazione per prelevare materiali da barili o IBC (Intermediate Bulk Container), stazioni di svuotamento sacchi, e opzioni di scarico big bag con adattatori per regolare il rapporto aria/materiale.
Trasporto di nutraceutici verso e da unità di miscelazione e blender, vibrovagli, V-blender e scarico di essiccatori a letto fluido
La miscelazione è un'operazione altamente complessa ed è essenziale avere la giusta soluzione di miscelazione e trasporto fin dall'inizio. Questo aiuta a garantire il controllo completo sui numerosi fattori che influenzano l'efficienza della miscelazione e la qualità del prodotto finale. I sistemi di trasporto Piab svolgono un ruolo fondamentale nel funzionamento efficiente dei processi di miscelazione nella produzione di integratori alimentari, incluso il caso speciale di alimentazione dei V-blender. Inoltre, vengono utilizzati nel processo per alimentare vibrovagli o scaricare essiccatori a letto fluido tra gli altri.
Trasporto del materiale per integratori alla riempitrice di capsule
Dopo la lavorazione primaria, come la miscelazione, la miscela di materiale per integratori, che sia in polvere o granuli, deve anche essere trasportata alle macchine di riempimento. I conveyor Piab trasportano il materiale per integratori alle stazioni di riempimento delle capsule, distribuendolo in modo efficiente.
Anche le capsule vuote devono essere trasferite dai contenitori di stoccaggio alle stazioni di riempimento. I conveyor vengono utilizzati per movimentare le capsule vuote in modo ordinato, garantendo un approvvigionamento continuo alle macchine di riempimento
Feed the tablet press
Productivity and workspace ergonomics can be greatly enhanced with Piab vacuum conveying. Feeding the tablet press becomes easy, and the ready-made tablets can be gently moved toward the tablet coater or to the packaging line. Segregation/separation of the raw materials in mixes and chipping of tablets are avoided with the appropriate Piab vacuum conveyor, which leads to increased efficiency and productivity.
Fill nutraceutical sachets
The Austrian Kora Füll GmbH uses piFLOW®p conveyors to fill superfoods efficiently into stick packs. Their decision was based on Piab's great local support, easy cleaning and maintenance, and enhanced occupational safety and comfort. In this example, their Piab vacuum conveyor runs with a 500kg/h capacity and conveys powdered materials to 10 meters distance.
Packaging of supplements and nutraceuticals
After the capsules are filled and sealed and/or the tablets are pressed and coated, they are typically packaged into bottles, blister packs, or other containers. Piab conveyor systems are used to transport the capsules or tablets to packaging, labeling, and capping stations for final processing before distribution.
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A solution for automation with many applications
The nutraceutical industry is a world between food and pharmaceutical industries and can cover various practices from functional food or food supplement production to sterile pharmaceutical production. This variety implies a diversity of requirements for manufacturing hardware, all while preserving product integrity is a standard requirement. Most conveying equipment has to be food-grade only, but in some cases, more rigorous rules apply, especially if the conveyed material poses a health risk to the operators.
piFLOW® for the nutraceuticals industry
Piab offers a wide range of vacuum conveyors for all these needs, including food-grade and antistatic ones with ATEX dust or ATEX gas certifications. To convey powders and granules, one of the piFLOW®p or piFLOW®c models is recommended, depending on the needed capacity, the material characteristics, and even the level of manual intervention from the operator at setup and ongoing use.
piFLOW®p is available with four different automation levels, ranging from the standard product to the completely automated Auto-tuning. To transfer tablets or other more vulnerable materials, we recommend using piFLOW®t, equipped with the piGENTLE® technology to avoid chipping the tablets during transfer.
Vacuum conveyors can be applied throughout multiple stages of the production line, including the charging and discharging of tablet presses, capsule filling machines, mixing and blending units, roller compactors, and auger fillers all the way to packaging. A common misconception about vacuum conveying is that it necessarily damages the product or leads to product separation in powder mixes. With the appropriate settings and the right sizing, Piab conveyors overcome these challenges, so you don't need to worry about variations in product formulation. The small footprint also allows for a flexible layout.
It was important to us that the conveyor can be cleaned not only in the shortest possible time but also thoroughly so that no residues of the previous produce contaminate the next - especially in the case of allergens, which would be an absolute no-go.
Why convey with Piab?
Fulfills the requirements
All Piab vacuum conveyors fulfill various requirements applicable across the nutraceutical industry. Our application engineers can help choose the right equipment to use.
Ensures productivity
The material supply is not dependent on the operator's physical capabilities and provides for a continuous process. Avoiding manual handling also contributes to better occupational health and safety, all while increasing system uptime.
Avoids product segregation
The powdered products stay consistent in the conveying process. Tablets and small particles, on the other hand, will not be damaged through the gentle conveying process.
Small footprint
Piab vacuum conveyors have a compact, modular design that allows them to be easily retrofitted, maintained, and cleaned. They also fit constrained spaces when they have to be mounted above bigger equipment, such as packaging machines.
piFLOW®p in real-life setting
piFLOW®p under maintenance
Operator inspects piFLOW®p
piFLOW®p feeding a sachet filling machine
piFLOW®p
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