Bossar’s R&D department is constantly developing new processes for applications and innovative systems. One of the latest completed projects comprises two lines, with two horizontal form, fill and seal machines (HFFS) each, packaging a powder for bone rebuilding. The first HFFS machine doses the powder in a flat pouch and the second machine places the first pouch in another pouch. After this step, the output of both lines is joined in order to go through a sterilization process before reaching a third HFFS machine that places each pouch into a third pouch. The result is a package containing a properly sterilized clinical powder duly protected to avoid any leaks.
The first pouch is made out of two film rolls of different material. The film enters one in front of the other through the guides and the sealing is done ultrasonically since they are non-compatible structures. The dosing is done via an auger filler and the machine is fitted with a dust aspirator and collector to avoid product waste. Through a multi-level grouping system, the pouches go via a conveyor that takes them to the second HFFS machine in which a funnel drops each pouch into a larger sized pouch. In the exit station the pouches are grouped and transported to a decontamination and sterilization system. After this, the pouches are taken to a third filling machine where the pouches are placed in a new pouch,
resulting in a packaged product ready to be used in the operating room.
Another interesting application developed by Bossar comprises the package of a plastic swab with a sponge containing a liquid that creates a protective layer in the treatment of superficial wounds. The machine utilized to comply with customers specifications was a personalized BMK-1400 machine. There are two filling stations — the first one dosing the liquid inside the pouch, and the second one introducing the swab in an inverted position so that the sponge gets in contact and absorbs the liquid for its future use.
The swab feeding system consists of a vibrating rotary bowl specially designed for this project — this ensures proper speed and positioning of the swabs, and a vibrator that pushes the swabs to guides, at the end of which a gripper rotates the swab 90° and places it in the pouch. As a safety measure, a detection system before the top seal has been designed in order to avoid any swab sticking out of the pouch, avoiding damage to the swab by the top seal.
