ALF – fill and seal machines for ampoules and vials

ALF – the convincing line concept

Output: Work and production considerations:

❒ Easy operator control due to the slim,
Up to 30.000/h.
tidy, clearly laid-out construction. Easy
cleaning.
The ALF series of machines meets all the ❒ All machine functions can be overseen,
prerequisites for modern ampoule produc- controlled and operated from one
tion. The convincing line concept. position at the front.
Wide experience, state-of-the-art know- ❒ Clean Room compliance.
how, highly developed engineering and ❒ Drive and production segments are
Bosch quality – new dimensions for clearly separated: worktop right through.
dependability, economy and flexibility ❒ Virtually tool-free size changeovers.
with easy operator control. ❒ Integrated testing technique, e.g. for
ampoule neck control (add-on device).
The ALF series was configured in accor- ❒ Laser sealing technique (add-on device).
dance with pathfinding, pharmaceutically
compliant findings to provide a modern,
ergonomic design that supplies the
customer with maximum benefits.
Decisive in this design is a basic machine
that can be equipped and retrofitted with
various equipment units. These include:
❒ In-process control system
❒ Closing station for vials
❒ Infeed and outfeed starwheel
❒ Laminar Flow hood
❒ Isolator version

ALF with the add-on equipment:

pre-gasflushing, post-gasflushing, closure
gasflushing and automatic, loss-free
in-process control.

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One basic machine for various equipment units

The ampoules are transferred directly from

the sterilizing tunnel to the ALF infeed belt.
Via a scroll conveyor and transfer wheel
the ampoules reach the conveying system
by means of which they are conducted
through the work stations: gasflushing,
filling, sealing. Each filling point controls
individually contactless scanning of the
ampoule necks – "no ampoule – no filling".
The ampoule necks are precentred by the
draw-off grippers, the ampoule tips are then
grasped and fed into a collection container.
During the sealing procedure post-gasflush-
ing can take place. The filled and sealed
ampoules are pushed virtually load-free
into the outfeed magazine.

Ampoule transfer wheel

ALF with the add-on equipment:

pre-gasflushing, post-gasflushing,
closure gasflushing and automatic,
loss-free in-process control.

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 Precision filling systems for all product properties
Time-pressure fill system and in-pro-
cess control. Time-pressure filling system.
Time-pressure filling system:
The Bosch time-pressure filling system is
successfully used for a wide range of
applications due to a multitude of advanta-
ges:
❒ Easy size changing with just a few low-
cost parts.
❒ Pressure and temperature acquisition are
located right at the filling point.
❒ Usable for all liquid products, especially
advantageous for shear-sensitive products.
❒ All parts in contact with product are sui-
table for manual cleaning and sterilizing
in an autoclave and for CIP/SIP.
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Rotary slide pumps.
Rotary slide pumps:
Bosch provides precision filling for parente-
ralia with its proven rotary slide pump.
Product-conserving and drip-free filling to
the highest degree of filling precision are
ensured for a wide range of different
properties.
Bosch seal-free rotary slide pumps have
easy vertical cleaning paths.
Technical in the lead:
❒ 3-part: rotary slide valve, pump cylinder,
pump piston.
❒ Seal free.
❒ Easy, vertical cleaning paths.
❒ CIP/SIP capability.
Rotary slide pumps made of stainless steel
and ceramic material.
Add-on devices, laser sealing technique
Sealing ampoules by the laser technique.
The energy required for preheating and
drawing off the ampoule neck is generated
by a CO2 laser. The system provides a
special advantage for ampoule fill and seal
machines that are equipped with an Isola-
tor. The laser unit is set up outside of the
Clean Room A. In comparison to conven-
tional sealing with gas and oxygen this
system is practically particle-free, flow-free
and produces considerably less heat.
Protective gasflush- Filling station
ing prior to filling (standard)
Laser sealing station
Due to this no elaborated extraction of heat
in the preheating and draw-off station is
required. Flame adjustment, which is
dependent on the glass and is often very
sensitive, is dispensed with. Due to storage
of the adjustment data the settings are
reproducible and at the same time a
considerably faster and simpler size change-
over results.
Inert gasflushing Gasflushing
after filling during closing
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 Add-on devices: in-process control, double outfeed

Discharge of containers into a tray for

in-process control.
Automatically switchable double out-
feed.

Discharge of containers into a tray for

in-process control. Fully automatic, loss-free in-process
control of the filling weight.

Fully automatic in-process control,

weighing position.

Fully automatic in-process control,

Touchscreen PC.

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Add-on devices: sealing station for vials

On the version of the processing of both

ampoules and vials the 4-point and 6-point
basic ALF machines can be equipped (and
retrofitted) for different size and output
ranges.

ALF multi-purpose machine for ampoules

and vials: right-angled outfeed via scroll
conveyor.

ALF multi-purpose machine, linear outfeed

via scroll conveyor.

Product containers with min./max. control

CIP/SIP time-pressure filling station, SIP gasflushing stations. unit mounted on the distribution pipe.

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 Right-angled feed and discharge conveyors, wall installation,
gasflushing

Feed star (with right-angled arrangement

ALF multi-purpose machine, right-angled of the sterilizing tunnel and on the multi-
outfeed scroll conveyor purpose machine). Right-angled discharge conveyor

Wall installation Gas installation package

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Size parts

Size set for standard machine.

Sizepart set for infeed,

with tunnel installed at right angle.

Size set for right-angled outfeed Size set for IPK.

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 Bosch is number 1 worldwide in Isolator engineering

The leading pharmaceutical companies

have set themselves the objective of
marketing innovative products, which is
why they back Bosch’s innovative Isolator
engineering.
In the pharmaceuticel industry Isolator
technology is gaining ever greater im-
portance due to its clear production
advantages. Comparisons with convention-
al sterile room technology have been dealt
with in a multitude of technical articles and
symposia. There is a clear trend towards
the Isolator technique.
The advantages of personnel and product
protection are what makes isolators the
technology of the future. Bosch has proven
its leading position because it has the
largest share of the total number of Isolator
installations supplied.

Slim construction.

Example of a compact ampoule

installation with separately standing ven-
tilation unit.

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Ampoule compact line

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Technical specifications

Containers, machine type, container size, output:

Type Vol. (ml) Ø (mm) H (mm) Adjusted throughput

Ampoules ALF 4040 1 - 30 9 - 30 60 - 160 1 - 2 ml: 200/min
ALF 4060 1 - 30 9 - 26 60 - 160 1 - 2 ml: 300/min
ALF 4080 1 - 30 9 - 22,5 60 - 160 1 - 2 ml: 400/min
Ampoules ALF 4040 2R - 30 R 14 - 30 35 - 75 2R: 200/min
and combi 5H - 30H 5H: 180/min
vials ALF 4060 2R - 30 R 14 - 26 35 - 75 2R: 300/min
combi 5H - 30 H 5H: 270/min

2750
2750
1085

900

2650

PA/ADV · 03/04 · 1 E · Arnold 73779 Deizisau · Paper: white, without chlorine © All rights reserved.
Graphic illustrations in this leaflet are
All dimensions in mm
examples only! Determinant for the final
execution, including technical specifications,
is our individual quotation exclusively.
Subject to technical modifications.

Robert Bosch GmbH Bosch Packaging Technology K.K.

Packaging Technologie Division Hatchobori NF Bldg., 4F
Pharma Business Unit 2-21-6, Hatchobori
Blaufelder Straße 45 Chuo-ku
D-74564 Crailsheim Tokyo 104 0032
Japan
Postfach 14 54
Telephone +81 3 3206 2821
D-74554 Crailsheim
Fax +81 3 3206 2822
Telephone +49 79 51 40 2-1 E-mail: vtjp@boschpackaging.com
Fax +49 79 51 40 2-2 58
E-mail: vt@boschpackaging.com Bosch Packaging Technology NA
Internet: http://www.bosch.de/pa Pharmaceutical
8700 Wyoming Ave. N
Robert Bosch Ltda. Minneapolis, MN 55445-1836
Tecnologia de Embalagem USA
Rua Dr. Rubens Gomes Bueno, 478 Telephone +1 763 424 4700
04730-901 São Paulo-SP/Brasil Fax +1 763 493 6711
Telephone ++55 11 5547 5709 E-mail: pharm-na@boschpackaging.com
++55 11 5547 5831 Internet: http://www.boschpackaging.com
Fax ++55 11 5547 5906
http://www.bosch.de/pa
E-mail: vtbr@boschpackaging.com IWF