Aseptic Filling Machine Format Conversion & Retrofit
A pharmaceutical manufacturer purchased an existing aseptic filling machine that was originally designed to process a different bottle, tip, and cap format than the format required for their current production. Rather than replacing the filling equipment, Capital Automation was hired to engineer and implement a complete format conversion, adapting the existing machine to reliably process the customer's new product configuration. The project required extensive mechanical engineering and modification of multiple critical machine assemblies. Many of the original format-specific components had to be redesigned, manufactured, and integrated while maintaining the functionality and precision of the existing pharmaceutical filling system.
The Challenge:
The existing aseptic filling machine was designed around a different product format. Changes in bottle geometry, tips, caps, and component dimensions meant that the original machine tooling could not reliably handle the new product.
The retrofit required modifications throughout several stages of the machine, including:
- Bottle feeding and unscrambling
- Bottle transfer and positioning
- Bottle rejection
- Product transport through the filling process
- Tip feeding and orientation
- Tip pick-and-place
- Cap feeding and orientation
- Cap pick-and-place
- Starwheel transfer and indexing
Because these systems operate together as one synchronized process, changing the product format required careful redesign of the individual components while maintaining proper alignment, timing, and product handling throughout the machine.
Our Solution:
Capital Automation performed a comprehensive mechanical retrofit of the existing aseptic filling machine.
The team evaluated the original machine tooling and redesigned the required format components around the customer’s new bottle, tip, and cap configuration.
Unscrambler Chute Redesign
The original bottle unscrambler chutes were redesigned to accommodate the geometry and dimensions of the new bottles.
The new components were engineered to provide controlled bottle feeding and reliable transition from the unscrambling system into the downstream machine process.
Bottle Rejection System Redesign
The existing bottle rejection mechanism was modified and redesigned for the new bottle format.
The updated system allows bottles to be properly controlled and rejected when required without interfering with normal production flow.
Moving Rack Redesign
The machine’s moving racks and product-handling components were redesigned to correctly support, position, and transport the new bottle format through the different machine operations.
Maintaining accurate bottle positioning was particularly important for downstream filling, tip placement, capping, and transfer operations.
Tip Pick-and-Place Redesign
The original tip-handling tooling was redesigned for the new tip geometry.
The updated pick-and-place system allows tips to be accurately picked, transferred, aligned, and positioned onto the bottles during the automated production sequence.
Cap Pick-and-Place Redesign
The cap pick-and-place tooling was also redesigned to accommodate the customer’s new cap format.
The new tooling provides controlled cap handling and accurate placement while integrating with the existing machine motion and operating sequence.
Vibratory Bowl Feeder Conversion
Both existing vibratory bowl feeders – one for tips and one for caps – were redesigned and modified for the new components.
The bowl tooling, tracks, guides, and discharge sections were adapted to correctly orient and feed the new tips and caps into their respective automated handling systems.
Starwheel Redesign
All required starwheels were redesigned around the new bottle geometry.
The new starwheels provide accurate bottle positioning and controlled transfer between machine stations while maintaining proper spacing and synchronization throughout the filling process.
System Retrofit Highlights
Complete aseptic filling machine format conversion
Existing pharmaceutical equipment successfully adapted for a new product format
Bottle unscrambler chute redesign
Bottle rejection system redesign
Moving rack and bottle-handling tooling redesign
Tip pick-and-place system redesign
Cap pick-and-place system redesign
Tip vibratory bowl feeder retrofit
Cap vibratory bowl feeder retrofit
Complete starwheel redesign
Custom mechanical engineering and manufacturing
Integration with the existing machine platform
Extensive modification of existing format-specific tooling
Reduced need for replacement of the complete filling system
Result
Capital Automation successfully converted the existing aseptic filling machine from its original product format to the pharmaceutical manufacturer’s required bottle, tip, and cap configuration. By redesigning the machine’s unscrambling, transfer, rejection, feeding, pick-and-place, and starwheel systems, the existing equipment could be repurposed for the customer’s current production requirements.
The retrofit allowed the manufacturer to retain and utilize its existing aseptic filling platform while adapting it to a completely different product format, avoiding the significantly greater cost and lead time associated with purchasing a new filling machine.
The project demonstrates Capital Automation’s ability to reverse-engineer, redesign, manufacture, and integrate complex pharmaceutical machine components, extending the useful life and production capabilities of existing automation equipment.
The Result :
The automated system increased production output while reducing the amount of manual material handling required in the process.
By automatically transferring multiple components from bulk containers to the production conveyor, the system provides a consistent flow of material to the downstream assembly process and helps the customer meet increased production requirements.
Five components picked per cycle
Automated bulk-container picking
Automated pick-and-place operation
Conveyor integration
Custom mechanical design
Electrical and controls integration
PLC and HMI programming
Machine guarding and safety integration
Complete machine assembly and testing
Installation and commissioning
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