KOCH machine brochure medplus
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Safe and reliable<br />
packaging:<br />
<strong>KOCH</strong> <strong>medplus</strong><br />
<strong>KOCH</strong> packaging expertise<br />
for Healthcare applications
02<br />
Expertise for Healthcare applications<br />
<strong>KOCH</strong> <strong>medplus</strong>:<br />
safety, quality …<br />
A strong brand for sensitive products<br />
… and sustainability<br />
PACKAGE THE<br />
SUSTAINABLE WAY<br />
03<br />
Everything it takes to satisfy your stringent demands<br />
when packaging medical devices, pharmaceutical and<br />
diagnostic products – and more: that is <strong>KOCH</strong> <strong>medplus</strong>.<br />
This brand stands for our comprehensive expertise<br />
and experience in this sensitive sector. It Is a quality<br />
mark denoting added reliability, technology, equipment<br />
features, and support<br />
Sterile packaging<br />
of an artificial knee<br />
joint in two blisters<br />
fitted into each other<br />
Package the sustainable way<br />
When it comes to sustainability, we focus on the<br />
whole picture: Protection of the environment through<br />
recycled or bio-based materials. Consistent reduction<br />
of materials used in the process and packaging. Brandoriented<br />
product presentation with multiple types<br />
of packaging made of sustainable materials. All our<br />
packaging is stringently tested and can be easily, safely<br />
and productively processed using <strong>KOCH</strong> packaging<br />
technology.<br />
Smart processes help save material<br />
We apply innovative methods to further reduce the use<br />
of material during the packaging process: Our patented<br />
Smart Heating process permits perfect regulation of the<br />
material thickness, while our software-based Smart<br />
Forming process controls pressure build-up in the mold<br />
cavity, resulting in optimized blister quality and a higher<br />
cycle rate. Further examples include temperature-controlled<br />
tools that ensure perfectly formed blisters from the first<br />
cycle, and special cutting processes that provide for significant<br />
material savings, especially for small products.<br />
Individual, sustainable packaging<br />
Whether cyclePac® and cycleBox® mono-material<br />
packag ing, folding boxes, cycleForm® made of formable<br />
paper, or blisters formed using sustainable film: Our<br />
experts customize every packaging design to match<br />
your product and your requirements, while meeting the<br />
three key objectives of the EU‘s plastic waste policy:<br />
Reduce – Reuse – Replace.<br />
Blister pack containing syringes<br />
The best type of packaging<br />
Whether transparent rigid blisters, soft blisters with reduced<br />
material usage, or sustainable packaging solutions; and<br />
whether small, medium or large batches sizes, individual<br />
products or sets: flexibility is the underlying principle of<br />
all <strong>KOCH</strong> packaging technology, achieved using a modular<br />
design concept for all our <strong>machine</strong>ry and packaging lines.<br />
The best packaging process<br />
Building on a basic module and additional components, we<br />
craft a cost-efficient, reliable packaging process that meets<br />
your specifications and complies with statutory requirements.<br />
For semi-automated sealing of preformed blisters<br />
or a fully automated forming, filling, and sealing process.<br />
Your <strong>KOCH</strong> <strong>medplus</strong> <strong>machine</strong> solution is complemented<br />
by an automatic product feed system, perfectly matched<br />
end-of-line packaging <strong>machine</strong>s, as well as marking and<br />
inspection systems in accordance with UDI or Track & Trace.<br />
2021<br />
Blisters for every need (from left):<br />
Solids, Diagnostics, Liquids and<br />
Medical devices
04 Brand <strong>medplus</strong><br />
05<br />
Optimum packaging<br />
of sensitive products<br />
Special skills in <strong>machine</strong> construction<br />
and consultation<br />
<strong>medplus</strong> packaging technology, the perfect choice for …<br />
Medical devices<br />
Catheters and tubing, suture<br />
material, implants, infusion sets,<br />
surgical instruments, dental<br />
products, etc.<br />
Blister pack containing syringe<br />
Safety, flexibility, and traceability are the three key factors when it comes to<br />
the planning of a blister <strong>machine</strong> or line for the packaging of devices for the<br />
medical industry. This calls for extensive know-how: of the sensitive products,<br />
the exacting market needs, and your unique requirements.<br />
Liquids<br />
Syringes and injection solutions,<br />
ampoules, vials, bottles and<br />
pens, inhalers and sprays,<br />
paste-like products, etc.<br />
In our Healthcare business unit, a team of specialists is committed solely<br />
to translating your needs into the best packaging process for your specific<br />
application. We manage, coordinate and support your project at all stages,<br />
bringing our expertise to the table – from A for requirements analysis, to<br />
S for start-up support – and take over full Implementation from start to finish.<br />
After successful commissioning, we are at your side throughout the entire<br />
<strong>machine</strong> life cycle, providing our Support & Services to ensure the reliable<br />
operation and maximum availability of your <strong>medplus</strong> packaging solution.<br />
Packaging technology with added value<br />
Under the brand name <strong>KOCH</strong> <strong>medplus</strong>, we offer you a wide range of equipment<br />
features and associated services. Whether a standard <strong>machine</strong>, a special com plex<br />
<strong>machine</strong>, or a highly flexible <strong>KOCH</strong> packagingLine <strong>medplus</strong>: GMP-compliant<br />
<strong>machine</strong> design and construction are just as important as cleanroom compatibility.<br />
Detailed documentation confirms the implementation of all specifications,<br />
thus verifying full functionality.<br />
Solids<br />
Tablet blisters in user-friendly<br />
wallets, individual weekly blister<br />
packs, etc.<br />
Diagnostics<br />
Diagnostic devices, dosimeters,<br />
matching and calibrating<br />
material, reagent test strips,<br />
quick tests, etc.<br />
Multipart sterile filter housing with tube and cable set<br />
REQUIREMENTS<br />
ANALYSIS<br />
? …<br />
CONSULTING<br />
PACKAGING<br />
DESIGN<br />
MACHINE<br />
DESIGN<br />
CONSTRUCTION<br />
OF THE MACHINE<br />
INSTALLATION,<br />
COMMISSIONING &<br />
START-UP-SUPPORT<br />
SUPPORT &<br />
SERVICES
06 Packaging types<br />
07<br />
The right solution for<br />
every type of packaging<br />
For a productive packaging process from the start<br />
In addition to attractive presentation, packaging should protect the product. Particularly in the<br />
case of sterile products, it should be completely tight to ensure hygienic conditions until opened.<br />
Another increasing demand is for eco-friendly packaging. The inclusion of patient information,<br />
as well as the easy opening or reclosing of the packaging are likewise demands we address. We<br />
design the packaging accordingly, attune it to the technical capabilities of your <strong>machine</strong>, and<br />
develop a productive packaging process.<br />
Productive with regard to primary and secondary packaging, and also in terms of the form and<br />
costs of production: simple and low-priced for mass products, more sophisticated for products of<br />
higher value. The key com ponent is an individually configured <strong>KOCH</strong> blister <strong>machine</strong> in <strong>medplus</strong><br />
design. This comprises a basic module for forming, filling and sealing (FFS), or just for sealing (S),<br />
plus additional components. The ideal solution also addresses the selection of suitable materials,<br />
the economical use of materials, and, if required, the separate recycling of the packaging materials.<br />
Face seal blister Trapped blister<br />
Blister with lid material<br />
Blister to blister (double blister) Clamshell<br />
S sealing<br />
KDT KS-PL KDT KS-PL KDT KS-PL<br />
KDT<br />
FFS forming filling sealing<br />
KBS-PL KBS-KF KBS-PL KBS-C KBS-KF KBS-KF<br />
KB-KF plus KS-PL in line<br />
Soft blister with lid material from roll cyclePac®<br />
cycleForm®<br />
cycleBox® Folding box<br />
S sealing<br />
KDT KS-PL<br />
KDT KS-PL<br />
KS-PL<br />
FFS forming filling sealing<br />
KBS-C KBS-KF KBS-PL KBS-PL<br />
KBS-PL<br />
Cartoners
08 Sealing and Blister Machines<br />
09<br />
Custom configured to<br />
meet your unique needs<br />
Modular packaging technology<br />
A prime example of <strong>KOCH</strong> packaging technology:<br />
the modular design of the KBS-KF <strong>medplus</strong> Blister Machine<br />
Package output<br />
Marking (inkjet, laser)<br />
Lid material feeder<br />
Labeler<br />
Forming material transport via chain conveyor<br />
Automatic product feeder<br />
Machine technology: individual and productive<br />
Regardless of whether it‘s a sealing or blister <strong>machine</strong>, semior<br />
fully automatic: In addition to the modular design that allows<br />
for consistent customization, every <strong>KOCH</strong> <strong>machine</strong> solution offers<br />
further compelling benefits: Significantly extended format range<br />
and large forming depth for superior processing of even largevolume<br />
products. Easily accessible <strong>machine</strong> structure allowing<br />
for fast format changes and simple maintenance. Ultra-modern<br />
control technology via IPC with user-friendly interface via touchscreen.<br />
Complementary components for product feed, inspection<br />
and labeling. Modules for space-saving grouping and end-of-line<br />
packaging suitable for transport – seamlessly integrated into the<br />
process and the central control system.<br />
Heating station<br />
Forming<br />
material buffer<br />
FORMING<br />
FILLING<br />
Leaflet placer<br />
SEALING<br />
Full or split cut punch<br />
Sealing station<br />
Punching station<br />
Forming<br />
material feeder<br />
Forming station<br />
Heating and forming station with smart heating<br />
for perfect regulation of the material thickness<br />
and smart forming for optimized blister forming<br />
Chain conveyor of<br />
the KBS-KF <strong>medplus</strong><br />
with forming station
10 Sealing and Blister Machines<br />
11<br />
Blister Machine KBS-C <strong>medplus</strong><br />
Whether syringes, suture material, catheters, surgical instruments<br />
or diagnostic products: Both versions of the KBS-C <strong>medplus</strong> package<br />
small and medium-sized batches in quick succession, at a high<br />
cycle rate, and in excellent blister quality. This is achieved by<br />
innovative processes, in cluding force vectoring that allows for<br />
optimum control of the sealing quality, even for complex cavities.<br />
KBS-C pro <strong>medplus</strong><br />
Highly flexible, individually configurable:<br />
our versatile allrounder for flexible and<br />
rigid film applications<br />
Technical data<br />
Forming area: 380 x 350 mm<br />
Forming depth: 50 mm<br />
Sealing format: 380 x 350 mm<br />
Designed to meet the highest demands, the next <strong>KOCH</strong> <strong>medplus</strong><br />
generation is a further compelling extension of our expertise. The<br />
innovative <strong>machine</strong> concept – that won the German Innovation<br />
Award ’21 – combines a large forming area and ultra-compact<br />
<strong>machine</strong> dimensions. This small footprint, plus straightforward<br />
construction and set-up, makes the KBS-C the ideal <strong>machine</strong> for<br />
use in normal packaging areas and cleanrooms up to ISO class 7.<br />
Output:<br />
12–18 cycles/min.,<br />
depending on<br />
packaging material/<br />
shape and sealing<br />
duration<br />
Based on a standardized platform, the blister <strong>machine</strong> is available<br />
in two consistently market-oriented variants: the KBS-C base<br />
<strong>medplus</strong> for packaging soft film blisters, that comes with an<br />
attractive entry-level price tag and a small footprint. And the<br />
KBS-C pro <strong>medplus</strong>, designed to allow individual configuration<br />
and flexible handling of soft and rigid forming materials.<br />
KBS-C base <strong>medplus</strong><br />
Blister types<br />
Compact, pre-configured, and favorably<br />
priced: the KBS-C base <strong>medplus</strong> for<br />
flexible film applications<br />
Blister with lid material<br />
from roll<br />
Soft blister with lid material<br />
from roll
12 Sealing and Blister Machines<br />
13<br />
Turntable Machine KDT <strong>medplus</strong><br />
Sealing Machine KS-PL and<br />
Blister Machine KBS-PL<br />
Blister <strong>machine</strong> KBS-PL – highly efficient packaging using<br />
proven technology – for blisters made of PVC and PET or<br />
sustainable films such as RPET, Bio-PET or PLA<br />
Turntable Machine KDT – here the basic<br />
version in GMP-compliant <strong>medplus</strong> design<br />
Technical data<br />
Blister depth: up to 70 mm<br />
Sealing format: 250 x 360 mm<br />
Sealing force: 30 kN<br />
Output: 12 cycles/min.,<br />
depending on<br />
packaging material/<br />
shape, and<br />
sealing duration<br />
The cost-effective packaging of small to medium-sized batches<br />
is where the KDT comes into its own with its low purchase price,<br />
reasonably priced format parts, economical energy consumption,<br />
and well-devised <strong>machine</strong> concept with state-of-the-art technology.<br />
The basic <strong>machine</strong> version incorporates a turntable with<br />
four sealing tools and a unit for thermal sealing.<br />
Extension options<br />
An additional card placer system allows the automated feeding of<br />
different packaging elements such as blisters, lid material from the<br />
roll, or as blanks or front cards for trapped blisters. The KDT <strong>medplus</strong><br />
can be automated with a product feeder and other components.<br />
The Sealing Machine KS-PL and the Blister Machine KBS-PL productively<br />
package large batches of the same or similar products. In<br />
addition to all standard or sustainable films, both reliably process<br />
cyclePac® quality cardboard. Characteristics of both <strong>machine</strong>s<br />
are the large format and sealing area – suitable, for example, for<br />
large-format, stand-up blisters or hanging blisters with a standard<br />
hanger hole – as well as the pallet section. This can be served<br />
manually or by a robot. The user-friendly, clear-cut design allows<br />
full control of the process at all times.<br />
Both <strong>machine</strong>s are suitable for a wide variety of medical devices in<br />
various packaging forms. They can both also be used for secondary<br />
packaging under cleanroom conditions.<br />
Technical data<br />
Forming area: 250 x 500 mm<br />
Forming depth: 67 mm<br />
Sealing format: 238 x 580 mm<br />
Output: 20 cycles/min.,<br />
depending on<br />
forming material,<br />
packaging shape/size,<br />
and sealing duration<br />
Blister types<br />
Blister types<br />
Face seal blister Trapped blister Blister with lid material<br />
from roll<br />
Blister to blister<br />
(double blister)<br />
cyclePac® cycleForm® Face seal blister Trapped blister Blister with lid material cyclePac® cycleForm® cycleBox®<br />
from roll
14 Sealing and Blister Machines<br />
15<br />
Blister Machine KBS-KF <strong>medplus</strong><br />
Exemplary version of<br />
Blister Machine KBS-KF <strong>medplus</strong><br />
with lid material from roll<br />
Longitudinal cutting<br />
station, ceramic knife<br />
for eye surgery in blister<br />
sealed with Tyvek<br />
Whether rigid or soft blisters, whether using standard or sustainable<br />
forming materials, whether sealed or a blister with lid material<br />
from the roll, Blister Machine KBS-KF <strong>medplus</strong> ensures high out -<br />
put for a wide variety of products. The large forming and sealing<br />
format as well as a maximum forming depth of 70 mm permit the<br />
processing of individual, bulky products or multipart sets.<br />
The optimum sealing technology is selected to suit the lid material.<br />
The robust, smooth-running chain conveyor allows accurate product<br />
transfer from station to station, as well as maximum <strong>machine</strong><br />
uptime. For one hundred percent quality control and traceability<br />
in accordance with UDI or tracking and tracing specifications, the<br />
<strong>machine</strong> can be fitted with appropriate inspection and printing<br />
systems – as is the case with all <strong>machine</strong>s and lines in the <strong>medplus</strong><br />
version.<br />
Technical data<br />
Forming area: from 150 x 300 mm<br />
t0 500 x 500 mm<br />
Forming depth: 70 mm<br />
Sealing format: from 150 x 300 mm<br />
to 500 x 500 mm<br />
Output: 30 cycles/min.,<br />
depending on packaging<br />
material/shape, and<br />
sealing duration<br />
Blister types<br />
Face seal blister<br />
Blister with lid material<br />
from roll<br />
Blister to blister<br />
(double blister)<br />
Soft blister with lid material<br />
from roll
16 <strong>KOCH</strong> packagingLine <strong>medplus</strong><br />
17<br />
Packaging competence<br />
every step of the way<br />
Integrated, safe, highly flexible: <strong>KOCH</strong> packagingLine <strong>medplus</strong><br />
4<br />
5<br />
Your requirements for a productive and flexible packaging<br />
process, our expertise in customized packaging solutions<br />
and our experience in turnkey projects. We combine<br />
all these factors to design a seamless, highly automated<br />
packaging concept, incorporating all individual<br />
processes to form a perfectly matched system – your<br />
<strong>KOCH</strong> packagingLine <strong>medplus</strong>.<br />
2<br />
1<br />
2<br />
3<br />
6<br />
In this line we bundle all our know-how, our comprehensive<br />
mechanical engineering, automation and software<br />
expertise. For a seamlessly integrated packaging<br />
solution. With the perfect <strong>machine</strong>s for your needs,<br />
selection and integration of the right modules for product<br />
feeding, grouping and final packaging. If required,<br />
we also add additional labeling, inspection and handling<br />
systems. Easy and safe operation is ensured by<br />
incorporating all components, including those from<br />
other manufacturers, in a seamless, end-to-end IPC<br />
control system.<br />
In each <strong>KOCH</strong> packagingLine <strong>medplus</strong>, fast, straightforward<br />
format changes ensure maximum <strong>machine</strong><br />
uptime, while the concept allows for processing of<br />
small – as well as large-format products. It is also<br />
possible to incorporate various types of packaging in a<br />
universal package – for optimized storage and logistics<br />
as well as easier retail handling.<br />
1 2 3 4 5 6<br />
Forming<br />
Filling<br />
(product handling)<br />
Sealing Punching Grouping<br />
End-of-line<br />
packaging
18 <strong>KOCH</strong> Support + Services<br />
Uhlmann Group 19<br />
<strong>KOCH</strong> Support + Services<br />
For highly productive packaging over the entire life cycle<br />
<strong>KOCH</strong> Support + Services is our comprehensive, modular portfolio with which we create an individual service<br />
package and support you throughout the entire life cycle of your packaging solution. What sets us apart: the personal<br />
support from specialists with in-depth technical training and years of experience – from our headquarters in<br />
Pfalzgrafenweiler to our locations and sales & services partners across the globe. In addition to traditional services,<br />
we offer you our K 4.0 digital services that simplify and speed up your operating and maintenance processes.<br />
And, with our K 4.0 smartpacks, you can benefit from digital service packages that translate into higher productivity,<br />
increased availability, and optimized overall equipment effectiveness.<br />
Building on its core expertise in pharmaceutical packaging solutions the Uhlmann Group today offers a broad range<br />
of high tech packaging <strong>machine</strong>s, services and digital solutions for the pharmaceutical, health care, consumer goods,<br />
food and agricultural market. We are represented in 19 locations and 14 countries around the globe.<br />
Uhlmann Pac-Systeme GmbH & Co. KG<br />
Comprehensive flexible packaging systems, services and<br />
digital solutions for pharmaceutical products<br />
Founded 1948<br />
Employees approx. 1,500<br />
Headquarter Laupheim (Germany)<br />
Subsidiaries Brazil, China, France, India, Russia,<br />
Singapore, Spain, Sweden, Switzerland,<br />
United Kingdom, USA<br />
<strong>KOCH</strong> Pac-Systeme GmbH<br />
Custom made packaging solutions and services for<br />
medical products, contact lenses and consumer products<br />
Founded 1969<br />
Employees approx. 400<br />
Headquarter Pfalzgrafenweiler (Germany)<br />
Subsidiaries Brazil, China, France, India, Russia, Singapore,<br />
Sweden, USA<br />
Customized service packages including traditional<br />
services and our digital K 4.0 smartpacks<br />
Technical support via hotline and e-mail,<br />
online support via remote access or on site<br />
Installation and commissioning<br />
Training<br />
Services that ensure high <strong>machine</strong> availability,<br />
from temporary production support to output<br />
optimization<br />
Original format and spare parts<br />
Automation and integration<br />
Repair and maintenance on site or at <strong>KOCH</strong><br />
Cremer Speciaal<strong>machine</strong>s B.V.<br />
Counting and packaging solutions and services for<br />
pharmaceutical, consumer and agricultural goods<br />
Founded 1949<br />
Employees approx. 170<br />
Headquarter Lisse (The Netherlands)<br />
Axito<br />
Production expert of the Uhlmann Group, manufacturing<br />
of mechanical parts and components<br />
Founded 2019<br />
Employees approx. 240<br />
Headquarter Laupheim (Germany)<br />
Subsidiaries Wrocław (Poland)<br />
Jinzhou Wonder Packing Machinery Co., Ltd.<br />
Economic packaging <strong>machine</strong>s and services for<br />
pharmaceutical applications<br />
Founded 1998<br />
Employees approx. 200<br />
Headquarter Jinzhou, Liaoning Province (China)
<strong>KOCH</strong> Pac-Systeme GmbH<br />
Dieselstrasse 13<br />
72285 Pfalzgrafenweiler<br />
Germany<br />
Phone +49 7445 181-0<br />
Fax +49 7445 181-50<br />
info@koch-pac-systeme.com<br />
www.koch-pac-systeme.com<br />
Concept and design: Volker Laucher, Grafik Design, Stuttgart, Germany 08/2022 e 500 We reserve the right to make alterations in line with technical development. Copyright © 2022 <strong>KOCH</strong> Pac-Systeme GmbH, all rights reserved