Horizontal cutting (CALICUT)
Precision calibration and cutting machine for pharmaceutical implants
Precision calibration and cutting machine for pharmaceutical implants
Cilyx expertise
New drug delivery systems, such as ocular implants or subcutaneous implants, require precise production with strict tolerances for the diameter and length of polymer filaments. The post-extrusion CaliCut system is the next generation of instruments for precise calibration of polymer filaments and their cutting into well-defined implants. Adapted to a variety of polymer formulations and application fields, the post-extrusion CaliCut system is a highly modular instrument that can be adjusted to meet a wide range of product specifications.
High Precision
The compact post-extrusion CaliCut system is placed right next to the extruder die, so the polymer filament can be directly guided through a 1D laser diameter gauge and onto the conveyor without major cooling. Based on the laser measurement, the conveyor speed is adjusted to pull the filament, allowing the diameter to be adjusted within defined tolerances. Depending on the extruder die, the CaliCut system can handle a nominal filament diameter of 0.2 mm to 6 mm. The nominal length of an implant can be set from 1 mm to 200 mm.
Our approach
The cutting of an implant is a crucial step, and smooth cutting surfaces are highly dependent on polymer formulation and the cutting method applied. Therefore, the CaliCut post-extrusion system can be equipped with two different cutting mechanisms: a rotary and a linear cutting blade.
Both cutters can be parametrized to ensure the best possible cut for any materials that are used. The ability to adjust for different cutting cone geometries makes it possible to produce cutting solutions for diverse qualities of product. As a production device, the CaliCut post-extrusion system can perform up to 600 cuts/min.
Benefits
CALICUT offers a compact solution for horizontal extrusion applications in labs.
It is CE-certified and meets all the requirements of cGMP and GAMP5 good manufacturing practices.
Maximum Flexibility
Before a filament enters the cutting section of the instrument, the length of the conveyor ensures sufficient cooling of the filament, allowing for cutting with maximum precision. To meet a wide range of polymer formulations and throughput needs, the instrument is available with conveyor lengths of 350 mm, 700 mm, or even 1200 mm. Cooling can be accelerated with compressed air.
The cutting of an implant is a crucial step, and smooth cutting surfaces depend greatly on the polymer formulation and the cutting method applied. Therefore, the post-extrusion CaliCut system can be equipped with two different cutting mechanisms: a rotary blade and a linear blade. Both cutters can be parameterized to ensure the best possible cut for all implant materials. Adjustment possibilities for different cutting cone geometries enable the realization of cutting solutions for various product qualities. As a production device, the CaliCut system is suitable for up to 600 cuts/min.
Pharmaceutical Application
The computer control of the CaliCut system is housed in a robust stainless steel enclosure that complies with GMP guidelines. It can be placed on or next to the instrument to best fit the production line layout. The user interface is easy to use, provides full access to all machine parameters, and monitors the analytical performance with a live diagram of the measured filament diameter. The software offers different user levels with customizable access rights, secure data export, and audit trail support for 21 CFR Part 11 compliance. The post-extrusion CaliCut system comes with comprehensive IQ/OQ documentation.
With its great flexibility and interchangeable parts, the CaliCut system can be configured for use in research and development as well as in commercial production.
Advantages
- Highly Modular instrument that can be adjusted to meet a broad range of product specifications
- High precision process
- Maximum flexibility to meet your requirements
- Compliance with 21 CFR part 11
- Suitable for both R&D and commercial manufacturing purposes
Do you need help?
See our frequently asked questions to find the answer, or contact us.
Artificial intelligence (AI) can offer several significant advantages in a production workshop. Here are some of the key benefits that AI can bring to a manufacturing environment:
- Process optimization :
- AI can analyze large amounts of data in real time to identify patterns, trends and inefficiencies in production processes.
- It can help optimize production parameters to improve efficiency and reduce costs.
- Predictive maintenance :
- By using sensors and monitoring systems, AI can predict potential equipment failures before they occur.
- This enables proactive maintenance planning, reducing unplanned downtime.
- Quality control :
- AI systems, including computer vision, can inspect and evaluate product quality in real time.
- This helps to minimize defects and maintain high quality standards.
- Adaptability and flexibility :
- AI can help automate production processes, allowing greater adaptability to changes in demand and more flexible production.
- Data driven decision making :
- AI can quickly process complex data to support decision-making.
- Predictive analytics and machine learning models can help optimize operational decisions.
- Reducing labour costs :
- AI-based automation can replace some manual tasks, reducing labor costs and allowing workers to focus on more complex tasks.
- Improving safety
- AI systems can monitor working conditions and prevent hazardous situations, helping to improve worker safety.
- Continuous innovation:
- AI encourages continuous innovation by enabling companies to explore new approaches and develop smarter solutions for production challenges.
However, it is important to note that successful implementation of AI in a production shop requires careful planning, adequate training of staff and effective integration with existing processes. Companies must also consider the ethical and social implications of automating and using AI in the workplace.
Managing a robotics project, especially when it’s the first time for a company, can be complex but crucial to ensure implementation success. Here are some tips to help manage such a project:
- Needs Assessment :
- Clearly identify the tasks or processes that the robot must perform.
- Analyze the expected benefits in terms of productivity, quality and profitability.
- training and awareness :
- Train staff on the use of the robot and explain the benefits of this technology.
- Involve the teams that will be directly affected by the robot in the process.
- Selecting the right robot:
- Choose a robot adapted to your company’s specific needs in terms of payload, speed, precision, etc.
- Also consider the safety and compatibility aspects with other equipment.
- Development of a detailed project plan :
- Identify the project milestones, timelines and responsibilities of each team member.
- Allow room for contingencies.
- Resource management:
- Allocate the necessary resources, including staff, time and budget.
- Make sure the team has the technical skills to manage and maintain the robot.
- Testing and validation:
- Perform thorough testing before commissioning to identify and correct any problems.
- Involve end users in the validation process to gather their feedback.
- Safety :
- Prioritize the safety of staff by implementing adequate security measures.
- Comply with current security standards and ensure that all personnel are trained in security protocols.
- Continuous communication :
- Communicate regularly with stakeholders throughout the project.
- Be transparent about progress, challenges and solutions.
- Maintenance and support :
- Develop a preventive maintenance plan to ensure that the robot is running smoothly.
- Make sure you have access to technical support in case of problems.
- Post-implementation evaluation:
- Evaluate the results after commissioning the robot.
- Identify lessons learned and use this information to improve future projects.
By following these tips, you will increase your chances of success in implementing your first robotics project. Cilyx can assist you in this process.
The combination of artificial vision and adaptive robotics represents real progress in various fields and offers several advantages. Here are some key aspects of these technologies and the benefits they bring:
- Flexibility and Adaptability :
- Adaptive robotics allow robots to adjust to changing environments and interact flexibly with their surroundings.
- Combined with artificial vision, robotics can recognize and react to unexpected objects and situations, improving the adaptability of automated systems.
- Reduction of Programming Time :
- Artificial vision can be used to teach robots specific tasks by simply showing visual examples rather than resorting to complex manual programming.
- This reduces programming time and enables faster commissioning of robotic systems.
- Improvement of Precision and Quality :
- Artificial vision allows advanced visual perception, allowing robots to perform tasks with high precision.
- This improves the quality of automated operations, especially in areas such as assembly, welding and inspection.
- Human-Robot interaction more Intuitive :
- By using artificial vision, robots can detect and react to human movements and actions, facilitating more natural interaction with human operators.
- This paves the way for safer and more efficient collaborative work environments.
- Adaptation to Product Variations:
- The combination of vision and adaptive robotics allows systems to adapt to product variations without requiring extensive reprogramming.
- This is especially beneficial in manufacturing environments where frequent product changes are common.
- Predictive maintenance :
- Vision systems can be used to monitor the condition of components and equipment.
- Adaptive robotics can respond to this data by anticipating maintenance needs, helping to reduce unplanned downtime.
- Reduction of Labour Costs:
- By automating complex tasks with advanced vision and adaptive robotics, companies can reduce labor costs and improve operational efficiency.
While these advances are promising, it is essential to consider potential challenges such as safety, ethics, staff training and change management when adopting these technologies. Successful implementation requires thorough planning and careful integration into existing processes. Cilyx can assist you in this process.
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Discover how our solutions can be tailored to your situation. Contact our experts to analyse your process and define the most relevant approach.