Bosch Packaging Services ServiceLetter - g-m.it · 2 | Bosch Packaging Services ServiceLetter Rotary valve pump – pump cylinder made from one piece Rotary valve pumps made of zirconia

Bosch Packaging Services

ServiceLetter

Upgrades and accessories for fi lling systems

Numerous upgrade and accessory kits are available for your fi lling systems.

Please get in touch with us - together we will fi nd solutions which best fi t your requirements.

ServiceLetter2 | Bosch Packaging Services

Rotary valve pump – pump cylinder made from one piece

Rotary valve pumps made of zirconia ceramics

The rotary valve, piston and sleeve are made of zirconia ceramics. The pump cylinder is made of aluminium oxide ceramics.In comparison with aluminium oxide ceramics, zirconia ceramics distinguishes itself by a higher fl exural and impact strength. The rotary valve pumps completely made of aluminium oxide ceramics are available as well.

The manufacturing process of the new pump cylinder distinguishes itself by the complete machining of this part from one piece. The manufacturing of the cylinder from one single material batch and consequently defi ned material quality of 1.4435 (316L) guaran -tees an absolutely homogenous material quality and traceability.


No matter if you need rotary valve pumps made of stainless steel, ceramic or CIP/SIP pumps, you will get significantly reduced prices when purchasing larger quantities.

We will be happy to provide you with a quotation.

Graduated prices for rotary valve pumps

Rotary valve pumps including material certificates

Material certificates can be obtained for our product-contact parts. Going forward, our rotary valve pumps include the following documents at no extra cost:

3.1 certificate Leak test reportCleaning and safety instructions

After inspection, individual pump parts such as piston, rotary valve or cylinder can be replaced with pumps manufactured from 2015. With the replacement, the material certificate is updated accordingly.

In addition, our scale prices for orders of min. 7 pumps still apply.

Your benefits

3.1 certificate included No additional costs Replacement of individual pump parts Scale prices

The documentation and traceability of batches produced in the pharmaceutical industry are of key importance.

Standard stainless steel pumps sent to us for pump repair are checked after receipt.

If the pump is repairable, you will receive an offer for the pump repair. The average repair time is about 8 to 12 weeks.

You can choose between a pump repair and the purchase of a new stainless steel pump from our stock at the price of the pump repair.

Replacement of repair pump with new pump

Your benefits

�immediately available��new pump from stock��pump at the price of a pump repair��one year warranty for new pump

If you decide in favour of a new pump, we will dispose of the defective pump free of charge.


Moistening cup with O-ring at piston

Moistening cup with O-ringMoistening cup at the piston of a ceramic pump

Moistening cups for rotary valve pumps Moistening cups are mounted at the piston or between the cylinder and rotary valve of a rotary valve pump. They are very useful if the piston seizes in the cylinder due to the specifi cation of the product, i.e. certain products slightly crystallize out and the piston no longer moves smoothly in the cylinder.

The moistening cup with the O-ring serving as a seal is mounted at the bottom of the piston or between the cylinder and rotary valve. Depending on the requirements, it is fi lled with alcohol, WFI or distilled water. The piston or rotary valve is permanently moistened by the liquid in the moistening cup. This largely prevents the piston from getting stuck.

Upper dead centre Lower dead centre

Cylinder

Piston

Utility (alcohol, WFI,

distilled water)

Seal (O-ring)

Moistening cup

Volume in ml Pump no. Machines Moistening cup incl. O-ring

0,3 – 1,5 8 109 314 018 ALK/ALF/FLS/MLD/FLM 8 109 027 242

1 – 5 8 109 297 099 ALK/ALF/FLS/MLD 8 109 027 244

5 – 25 8 109 314 024 ALK/ALF/FLS/MLD 8 109 027 245

20 – 50 8 109 039 640 ALK/ALF/FLS/MLD 8 109 269 491

250 8 109 258 738 MRF/FLM 8 109 016 847

Moistening cups for standard pumps


This device was developed for the non-contact rotary valve pump mounting into the pump support of our fi lling machines.

The pump consisting of a cylinder, piston and rotary valve is positioned in the pump mounting device in correct position so that the pump parts cannot be mixed up.

Pump parts are prevented from getting loose during the mounting and dismounting of the pump. As a result, damage to the pump parts is avoided.

By means of this device, rotary valve pumps can be mounted and dismounted quickly and safely with one hand. Set-up times are reduced.

Alternatively, a pump mounting device version is available which allows for the sterilization with the pump parts remaining in the device. By pulling the frame apart, the careful sterilization of all individual pump parts can be ensured.

Pump mounting device for rotary valve pumpsThe pump mounting device is an ideal mounting and dismounting aid for rotary valve pumps.

In the sterile room or isolator, pump mounting with gloves is diffi cult.

With this device, it is possible to mount the pump with one hand only. The parts of the device which are in contact with the rotary valve pump are made of Tecapeek.

During sterilization in the autoclave, the part are resistant to deformation even with high temperatures. All other parts are made of stainless steel (316L). Process safety during batch or size change is increased by this non-contact assembly.

The pump mounting device is especially suitable for appli-cations in isolators and barrier systems.


To facilitate the cleaning and sterilization process, we offer special trays.

The unit consists of a universal base frame made of stainless steel, material 1.4435/1.4404 (316L), and is stackable and portable. The base frame accommodates one large or three small trays.

Carrying plates, which are available in two sizes, are inserted into this frame. These carrying plates, which are also made of 1.4404 (316L), can be used for all pump types and versions of the Pharma Liquid standard range of products.

The carrying plates come with base plates and supports where the pump parts such as cylinders, pistons, rotary valves, sockets, union nuts and sealing elements are plugged.

The supports of the base plates are designed in a way that the pump parts to be sterilized do not touch each other. So all pump parts can be cleaned and sterilized perfectly all over. Due to this orderly storage it is guaranteed that no pump part is missing.

Storage and sterilization tray for rotary valve pumpsThe sensitive rotary valve pumps of the fi lling machines have to be cleaned and sterilized regularly in accordance with the strict pharmaceutical regulations.


For a better protection of the rotary valve pumps the central overload clutch for the pump stroke was replaced with indi-vidual overload clutches at each pump micro adjustment unit. If a problem occurs at one pump, the overload clutch disen-gages and the machine stops immediately. This upgrade can be implemented on all AVRs and ALKs.

Your benefi tSignifi cantly increased safety for each individual pump.

Overload clutch for rotary valve pumpsPump micro adjustment with overload clutch

Seal kit for CIP/SIP pumps

A seal kit acc. to USP class VI is available for all CIP/SIP pump sizes. The seals, which are made of platinum-cured silicone, distinguish themselves in terms of excellent product compatibility. The pump seal kit consists of the fl at seals for product feeding and rinse lines as well as the O-rings for sealing the rotary valve and piston.

Considering replacing the seals of your CIP/SIP pumps in the near future?

Seal kit for CIP/SIP pumps


Laser welding of fi lling needles

Laser welding of fi lling needles

When manufacturing fi lling needles, Bosch relies on laser welding. With laser welding, the materials are connected with -out fi ller metals. There is nearly no secondary heat due to the short time span from melting to hardening of the metal.

Material stress is reduced to a minimum by selective energy supply. Structural changes and distortion are thus largely avoided.

For your Bosch machines we recommend that you stock a suffi cient number of fi lling needles to ensure the smooth operation of your fi lling and sealing machines.To facilitate stock control and procurement planning of these consumables for you, we have fundamentally revised ourpricing structure on these vital parts.You will benefi t from our attractive scale prices when you purchase fi lling needles in larger quantities, as illustrated in the discounts below:

From 6 pieces: – 25% bis – 35% *From 12 pieces: – 35% bis – 45% *From 24 pieces: – 40% bis – 50% *

* depending on type of fi lling needle

Scale discounts for fi lling needles

Your benefi ts

�Genuine Bosch quality parts at competitive prices��One-stop shop for technical know-how and servicing��Excellent stock availability

We would be happy to assist you in planning your long term needs. Please do not hesitate to contact us for more information.

1

4 2

3


Filling needles made of TECAPEEK™

Due to their stiffness and strength the TECAPEEK needles can also be used for warm fi ll products. The fi lling accuracy and performance correspond to the traditional stainless steel needles.

In comparison with stainless steel needles, they have a lower weight which facilitates the loading of autoclaves. Besides autoclaving, the TECAPEEK needles can be cleaned by gamma sterilization.

Filling needles made of TECAPEEK are suitable for all Bosch fi lling systems. As a standard the following sizes are available: outer diameter 2.0 to 8.0 mm (<2.0 mm on request).

Your benefi ts

Metal ion free filling Suitable for warm fill products High chemical stability Low weight Good cleanability

The handling of this device, which can be used fl exibly and transported easily, is simple: after inserting the needle (1) in the holder (4), the slide (2) is moved towards the needle. The interchangeable centering pin (3) checks the concentricity of the needle by turning the holder. If necessary, the needle is readjusted and subsequently double-checked in the device.

Defective and/or bent needles can thus be straightened and used again. You therefore do not have to obtain new needles, which saves you money on new parts.

By regularly checking your needles, you can ensure constantly high productivity and quality with the fi lling and gassing by your machines. Reject and downtime of your machines by defective needles are avoided.

Needle testing and adjusting device

Thanks to its interchangeable needle holder, this device is suitable for all types of fi lling and gassing needles. For the different machine types (ampoules, cartridges, vials or syringes) only one device is needed.

Your benefi ts

Versatile use of the device High process safety of your equipment Increased productivityLower reject rate and less downtime Cost savings

TECAPEEK (Polyetheretherketone) fi lling needles are available for products which have to be fi lled metal ion free or which are sensitive to metals. This FDA-compliant material has a very good chemical stability. The needles are therefore insensitive to cleaning agents or corrosive products and even resistant against oxidizing agents such as acids.


Filling needle monitoring upgrade The fi lling needle monitoring upgrade can be implemented on the machine types FLP, FLC, FLM, MLD, MRD, MLF and MRF.

sensor

refl ector

Sensor and refl ector with laser beam

This upgrade kit for the fi lling station consists of a sensor and a refl ector. In addition, new fi lling needles are needed for the modifi cation.

The fi lling needle monitoring ensures that the machine stops immediately if a needle does not hit the object and is therefore pushed up.

Due to the incorrect position of the fi lling needle the laser beam between the sensor and the refl ector is interrupted, and the safety mechanism is thus activated.

Filling needle pushed up

Your benefi ts

Increased production reliability Reduced risk of incorrect filling Prevention of contamination with product Simple upgrade

This safeguard minimizes the risk of damage on the fi lling needles. Contamination of the machine with product as well as incorrect fi lling due to defective needles are reduced or avoided respectively.

The upgrade can therefore be recommended especially if expensive and high-quality products are fi lled.

The upgrade by a Bosch fi tter, including programming changes, will take no longer than 1 working day.


If different ampoules / vial sizes are run on a machine, the following parts are needed for the bottom-up fi lling: ��fi lling needle lifting cam, synchronously ascending

with fi lling level, with fl ange and eccentric bolt (depending on object and fi lling volume)

��pump stroke cam (required one time)��fi lling needles (depending on object)

Filling needle lifting camsThe fi lling needle lifting cam synchronously ascending with the fi lling level makes the fi lling needle insert into the object until it reaches the object bottom. Then the needle ascends with the rising fi lling level, thus largely preventing the product from foaming.

Pump stroke camA new pump stroke cam is assigned to the different fi lling level cams for the bottom-up fi lling.

1/3 Filling��The fi lling needle is directly at the object bottom until one

third of the object is fi lled ��The fi lling process starts slowly

2/3 Filling��The fi lling process in the product is getting faster and

accelerated continuously until the end.��The fi lling needle is below the fi lling level until the end

of the fi lling process.

Filling needlesLonger fi lling needles are required.

This upgrade can be implemented on old machine types as AVR, ALK and FLP.

For optimizing the fi lling process especially with heavily foaming products, the fi lling needle lifting cam is adapted exactly to the fi lling volume and the object (synchronously ascending movement).

Bottom-up fi lling Advanced TPF (Time-Pressure Filling system) control systemThe TPF (Time-Pressure Filling) control system has been developed further and is replaced by an new system.

For older systems some of the components are no longer available. Please ask for our separate upgrade information.


Peristaltic pump

A distinct advantage of the detachable version is that it is much simpler to clean. All types of the Bosch peristaltic pumps, both for single and multiple-use dosing systems, are used in connec-tion with platinum cured silicone hoses. The easy handling of the product path (hoses etc.) on the pump is very user-friendly. Furthermore, the product loss is very low due to minor dead volume during start-up and run-empty. All peristaltic pump versions and sizes are available as a stationary pump station mounted on the machine or a fl exible solution on a moveable trolley.

The large pump head is suitable for fi lling volumes from 20 to 500 ml. In addition, a smaller fi lling head is also available for fi lling volumes from 0.1 to 30 ml. Together these two sizes cover an extensive fi lling range and are characterized by high fi lling accuracy.

Another ground-breaking innovation is the detachable version of the pump heads. The two pump head sizes can be swapped quickly and easily, as production requires. The tool-less replace-ment can be carried out with one hand.

Thanks to the newly developed large pump head, volumes up to 500 ml can now be fi lled with the Bosch peristaltic pump (also called hose pump).

Whilst working to enhance the peristaltic pumps, Bosch also focused on optimizing the hose quality. After extensive tests, a compliant hose was developed, manufactured in platinum-cured silicone, with FDA conformity acc. to CFR 177.2600 and USP class VI. The use of this Bosch-specifi c hose, which can be obtained exclusively from Bosch, ensures adherence to fi lling tolerances and functional reliability. In addition to the benefi ts of using it for the peristaltic pump, it is also ideally suited as peristaltic hose in the Time Pressure Filling System (TPF). This hose is available in 5 m and 15 m units.

On top of the spare parts number and the inner diameter it is marked with “small” for the 0.1 to 30 ml or “large” for the 20 to 500 ml pump head.

Hose for peristaltic pumpThe use of a correct hose is essential for the proper functioning of the peristaltic pump.


With the new Bosch hose cutting device 8-113-037-327 all hoses with an outer diameter between 2.9 and 14.3 mm can be cut quickly and easily. The working area ranges from a length of 50 to 270 mm.

The device consists of:

� Base plate � Scale ruler (not calibrated) � Variable end stop, lockable in position � Bosch standard cutting unit

The device comes with 10 replacement blades for the cutting unit.

Hose cutting device for cutting peristaltic hoses to the required length

Your benefi ts

Quick and precise cutting to size of hoses� Easy exchange of Bosch standard cutting unit�Handy size

Hoses for peristaltic pumps are usually sold by the metre and therefore have to be cut to the required length.


Enhanced fi lling level sensor at product tank

For the newly developed sensor a new sensor amplifi er, part no. 8 109 528 031, with angled connector is available. The amplifi er is supplied with cable part no. 8 109 522 721. The cable plug connection allows for easy assembly.

With the scaled and detachable turning knob at the sensor amplifi er the switching threshold can be adjusted precisely and without any tools, i.e. a screwdriver is no longer needed. The set value is maintained by simply removing the turning knob.

The amplifi er comes with status LEDs to visualize the switching status and error messages. The switching status “opening/closing“ can be set via a wire connection, so the previous risk of mixing up the setscrews is excluded.

8 109 524 815 Filling level sensor

8 109 528 031Sensor amplifi er, pluggable version

8 109 522 721 Cable for sensor amplifi er

The new fi lling level sensor can be used with both the new and old amplifi er part no. 8 109 509 677.

For the easy upgrade of the product tank with the new fi lling level sensor a modifi cation kit consisting of �sensor adapter 8 109 974 416�2 x threaded pin 8 108 190 207is available.

For mounting the sensor the standard ports at the product tank can be used.

Changes in the electrical system and software are not required.

With the tri-clamp seal the new capacitive fi lling level sensor 8 109 524 815 ensures maximum tightness during autoclaving, even after a large number of autoclaving cycles. In addition, better sealing towards the product is ensured during the fi ling process. For the tool-less assembly tri-clamp seal 1½“ part no. 8 108 192 100 as well as the tri-clamp seal part no. 8 109 523 739 are needed.

You will fi nd your local partner at: www.boschpackaging.com

02/2016 | PA-CS/STP2 | Bosch Packaging Services AG (subject to alterations)

Documents

Bosch Packaging Services ServiceLetter - g-m.it · 2 | Bosch Packaging Services ServiceLetter Rotary valve pump – pump cylinder made from one piece Rotary valve pumps made of zirconia