INTERNATIONAL MACHIINE CONCEPTS

IMC-60B Automatic Aluminum Tube

Filling & Sealing Machine

OPERATION

MANUAL

Page 1 of 39

CONTENT

1. Use Instructions

1. Summary 2. Working Principle 3. Technical Parameters 4. Structural Features 5. Equipment Transportation and Installation 6. Safety Notes 7. Operation Procedures 8. Operations of Touch Screen 9. Basic Adjustments 10. Adjustment of Automatic Tube Feeding

System 11. Adjustment of Transmission Part 12. Disassembly and Cleaning 13. Daily Maintenance 14. Common Malfunctions and Troubleshooting

2. Packing List

3. Certification

4. Electric Circuit Diagram (Attachments)

Page 2 of 39

1. Summary

produced by our company has such features as smooth and flat surface, free of

dead corner, being innoxiously and non-smell, free of pollution, easy cleaning,

and easy maintenance and servicing.

Thanks to the compact structure, simple and convenient operation, the machine is

applicable to the demands of users from the industries such as medicine, food

and daily chemical industry etc. The machine can smoothly and accurately fill

various paste, ointment and viscous fluids etc. materials into the aluminum tube

through the filling system. The operations such as filling, sealing and batch No.

printing (date of manufacturing) etc. for aluminum tubes can be realized through

the folding mechanical hands. The highest production capacity of the machine

can reach 3000 pieces/hour with an error of filling volume not more than ±1%.

2. Working Principle

Put in order the aluminum tubes to be filled on the tube bucket. Through the Thank you for

your using the automatic aluminum tube filling & sealing machine produced by

our company.

With the design, manufacturing, assembly, debugging, as well as main parts and

materials being fully in accordance with GMP requirements, the automatic

aluminum tube filling & sealing machine automatic tube feeding device, they

will be automatically inserted into the cup seats (positioning molds). The cup

seats will rotate with the rotary table so that they will be positioned at different

work stations. Put the ointments for filling into the lockable cone hopper.

Through the plunger type quantitative filling valve directly connecting with the

hopper, they will be accurately and automatically filled into the aluminum tubes

staying at intervals on the work stations of filling. The rotary table will continue

its rotation and rapidly bring the aluminum tubes that have been filled with

ointments to different work stations of sealing. The mechanical hand at each

Page 3 of 39

work position will instantly seal the tube tail. Different filling volumes can be

achieved through adjusting the filling volume adjusting dial. The sealing

operation of aluminum tubes with different folding forms such as two-side

folding, three-side folding and saddle-shape folding can be finished through

changing different mechanical hands. After the sealing is finished, the

mechanical hand for code printing will automatically print the words such as date

of manufacturing and production batch No. onto the tube tail. Through the

automatic tube discharging structure, the finished tube will be automatically sent

into the tube collecting vessel.

3. Technical Parameters

Filling range: 5-150ml/tube (adjustable)

Filling accuracy: ≤±1%

Production speed: 1800-3000 tubes/hour

Aluminum tube diameter: Φ10- 32mm

Aluminum tube length: 185mm (max. length)

Hopper volume: 40 L

Power supply: 380V/220V (optional)

Air pressure: 0.5-0.7MPa

Machine power: 2 kw

Motor power: 1.1kw

Outline dimensions: 1900(L)×850(W)×1900(H)mm

Machine weight: about 850kg

4. Structural Features

1. Reasonable structure design

The machine has fully embodied the design conception of advancement,

reliability, reasonability of pharmaceutical equipment required by GMP, and

artificial factors have been reduced during the use. Linkage design is adopted for

Page 4 of 39

the automatic feeding of tubes, the automatic positioning of tube color codes,

filling, sealing, batch No. printing and discharging of finished products so that all

the actions are synchronously completed.

2. The requirements of materials to filling technology have been fully satisfied.

a. The machine has compact structure with short time from filling to sealing.

And complicate sealing forms can be completed.

b. It is guaranteed that there is no pollution during the filling process. The

parts in the machine that contact the materials are all made of 316L

stainless steel materials and complete polishing treatment is carried out on

the contacting surfaces.

c. High filling accuracy. The machine adopts reliable piston type quantitative

filling valve, which is provided with convenient and reliable adjustment of

the filling volume and high filling accuracy.

Page 5 of 39

21 3 45 6

7

89

10

11

Figure 1 Schematic Figure of Main Machine 1. Electric Box

2. Hopper

3. Frame

5. Main Transmission Haft For Sealing

6. Tube Feeding Part

7. Profiling Lifting Head

8. Mechanical Hand

9. Filling Nozzle

10. Filling Volume Adjusting Hand Wheel

11. Motor

Page 6 of 39

d. Easy assembly and disassembly of filling assemblies. The bucket valve

body and piston filling head etc. can be rapidly disassembled and it is easy

to carry out cleaning, disinfection and sterilization.

e. During the filling, the filling nozzle can be extended into the tube, so as to

ensure effective filling and prevent the sealing quality from being

influenced as a result of material adhesion on the tube wall.

f. The air blowing device is additionally installed. The filling head adopts the

combined blow-out and cut-out filling mode so as to prevent the sealing

quality and filling volume being influenced as a result of long wire drawn

out by the materials of high viscosity.

3. Multifunctional sealing structure with easy adjustment

The two-side folding, three-side folding and saddle-shape folding etc. different

folding forms of aluminum tubes can be conveniently and accurately adjusted

according to requirements of users.

4. The operating parts of mechanical hand completely adopt fully enclosed ball

bearings, and the upper and lower sliding shafts on the machine table surface

adopt linear bearing and self-lubricating system so as to avoid pollution.

5. The automatic filling & sealing machine adopts frequency conversion step less

speed adjusting system, and the operation implements coordinated linkage

control so as to achieve a higher production speed. The pneumatic control

system is provided with precise filter with stable pressure of certain amount

being maintained.

6. The movement system is allocated with safety clutch, which can effectively

realize protection for fault overload.

Page 7 of 39

7. Beautiful appearance and easy to be cleaned

With beautiful appearance and compact structure, the machine is elaborately

made by adopting stainless steel polishing, and its table surface is easy to be

cleaned without any dead corner, which are fully in accordance with GMP

requirements for medicine production.

5. Equipment Transportation and Installation

1. Transportation and Placement

It is transported by wood pallet and forklift. Select a flat and dry indoor place,

after the filling & sealing machine is stably placed and unpacked. Adjust the

base bolts to level the main machine. The installation plan is as follows:

Air supply inlet

Tube bucket

Operator

Main machine

Power interface

Power distribution cabinet

Machine bottom corner Cold water inlet Cold water outlet

2. After it is unpacked, please check the followings:

△ Check if the machine is in accordance with your order according to the

instructions.

△ Check if there is any damage or cut that may influence the use caused

during the transportation. If the above problems are found, please

Page 8 of 39

immediately contact the sales department of our company for a proper

treatment.

3. Installation of tube bucket

Install the tube bucket onto the main machine and adjust the position of the tube

bucket, which shall be kept vertically upward with nuts tightened.

4. Allocation of power supply

The equipment adopts a 3-phase 380V four-line or a 3-phase 220V AC power

supply. The user shall make sure there is reliable grounding when connecting it

with the power supply, so as to guarantee personal security.

5. Allocation of air supply

The equipment adopts an air supply of 0.5-0.7Mpa. The air supply allocated by

the user shall be stable and the air displacement shall be not less than 0.6m3/min

so as to guarantee the reliable operation of cylinder and achieve a precise filling

effect.

6. Safety Notes

1. Before using the machine, please clean the surroundings. There

shall have no dangerous articles or other foreign matters.

2. The machine is provided with protection of safety door. After the

door protection functions, the machine will be stopped when the

door is opened. It is strictly forbidden to operate the machine

without starting the door protection, or else, accidents may take

place.

3. There is high voltage inside the electric control box of the machine.

Page 9 of 39

Unprofessional or untrained persons are forbidden to open it.

4. Make sure that the machine body is reliably grounded before the

machine is operated

5. The operator shall pay special attention to the parts where safety

warning marks are labeled on the machine body.

6. It is strictly forbidden to open the back cover of casing at the

transmission part when the machine is operated, or else, personal

injury may be caused during the operation.

7. Parts that do not conform to the machine performance can’t be

additionally installed and the machine can’t be modified. Otherwise

accidents may take place.

8. In case of emergency, please press the red emergency stop button

and eliminate the malfunction in time. If it is necessary to restart the

machine, make sure that the malfunction has been fully eliminated.

The main drive system of the machine is located at the bottom of the machine table

and is closed by a stainless steel door with a lock. When adjusting the filling volume,

a special person (an operator or a maintenance technician) shall be designated to

carry out the adjustment. Before restarting the machine, make sure that all the doors

are fully closed.

7. Operation Procedures

1. First check if there is any abnormal article on the surface of the

machine.

Page 10 of 39

2. Check if the aluminum tubes and materials are in good condition.

3. Open the electric control box, switch on the power switch and turn on

the general key switch and main machine switch.

4. Turn on switches for filling, color code, cleaning and tube feeding. If

it is necessary to count, please also turn on the counting switch.

5. If there are heat preservation and stirring systems, please turn on the

heat preservation switch and set the temperature required for heat

preservation on the heat preservation and heating control meter. And

then turn on the stirring switch.

6. Turn on the air pump switch or switch on the air supply. Adjust the

pressure adjusting valve, and make sure the numbers displayed on the

air pressure gauge is the set air pressure (the air pressure value is

generally 0.5-0.7MPa). Press the emergency stop button to reset,

press the inching switch, and then restart the main machine.

7. The machine shall be operated by qualified person after being trained.

Others can’t operate the machine randomly, or else, there may be the

danger of human injury and machine damage.

8. Carry out idle operation for 1-2 minutes every time before filling.

Check the operation status of all parts of the machine, which shall

realize that the working status shall be stable with steady running and

without abnormal noise, the adjusting devices shall function normally

and the instruments and meters shall work reliably.

Page 11 of 39

VIII. Operations of Touch Screen

1. Turn the combination switch to the position

2. Turn the key clockwise to turn on the power supply. At the time, the

power indicator lamp will be on and the human-machine interface

will be on. The main menu will be displayed (figure 8-1). Click

OPERATION button to enter into the operation window (figure

8-2).

Figure 8-1 Figure 8-2

Click MAIN MENU button to enter into door protection control window.

When the door protection is on, during the normal operation of the

machine, if the door is suddenly opened, the machine will immediately

stop its operation and the touch screen will indicate that the door is not

closed (figure 8-3).

Page 12 of 39

Figure 8-3 Figure 8-4

Touch NEXT to enter into the window for adjusting coder parameters

(figure 8-4). If the materials are thin with higher viscosity, we can adjust

the parameter values of fill on, fill off and blow on, so as to solve the

problem of wire drawing of filling nozzle. Touch DEBUGGING

OPERATION button on the main menu to enter into the window for

adjusting inching operation (figure 8-5) and carry out manual operation.

Figure 8-5 Figure 8-6

3. When there is any malfunction in the transmission mechanism, the

safety switch at the bottom of the machine will be triggered, and the

overload window will be displayed. Please cut off the power supply

Page 13 of 39

and eliminate the malfunction before restarting the machine (figure

8-6).

8. Basic Adjustments

1. Install the five mechanical hands according to the dimensions on the

installation figure of saddle-shape folding.

Adjustment of the first mechanical hand

1. Adjust the eccentric shaft on the internal and external mechanical

arms to make the two mechanical arms vertically at the center of the

cup seat (refer to the following figure 1). Adjust the internal and

external mechanical claws to make the interval between the internal

and external mechanical claws at about 0.5mm. (refer to the

following figure 2).

2. Note: The following adjustment is made by referring to the

5mm folding width of finished aluminum tube.

The height of the two mechanical claws shall be the one where they flatten

the tube tail for 25mm (refer to the following figure 4). The insertion board

shall be adjusted to keep a certain distance with the concave and convex

hinges (refer to the arrow indicated in the following figure 3).

Page 14 of 39

Adjustment of the second mechanical hand

1. Adjust the seat for external mechanical hand to make its bottom

parallel to the bottom of the mechanical arm (refer to the arrow

indicated in the following figure).

Page 15 of 39

Note: The adjustments shall begin from this position and during the

adjustment, the position shall be guaranteed to be unchanged.

2. Adjust the eccentric shaft on the internal and external mechanical

arms to make the two mechanical arms vertically at the center of the

cup seat (refer to the adjustment of the first mechanical hand for

details). Adjust the internal and external mechanical claws to make

the interval between the internal and external mechanical claws at

about 0.5mm. (refer to the above figure).

3. Rock the pulley manually to raise the lifting shaft to the highest

point. Adjust the positions of the insertion board and mechanical

arms according to the following figure. Pay attention to the arrow

direction.

Page 16 of 39

Note: The steps 1, 2 and 3 shall be synchronously operated.

4. Confirm the height of the rotary table according to the length of

the aluminum tube (4mm is recommended).

Page 17 of 39

5. Working state: During the operation process of the folding claw at

0-90°, the external mechanical hand will not move. During the

rotating process of the folding claw at 90°-300°, the upper wall of

the external mechanical claw and the inner wall of the folding claw

will make a parallel movement with an interval of 2mm between

them (refer to the following figure 1). At the time, the folding claw

will have a transient pause, and the external mechanical claw will

continue to move. At the same time, the lifting shaft will continue

to descend until the lowest point. From figure 2, we can observe

that there is an interval of 2-3mm between the external mechanical

claw and the folding claw. Only in this way, can it be guaranteed

that the external claw will not block the tail of the aluminum tube

(refer to the following figure 3). The folding claw will continue its

rotation and the external mechanical claw will draw close to the

inside to flatten the tail (refer to the following figure 4). Thus, the

whole folding action is completed. Note: When the lifting

Page 18 of 39

insertion board descends to the lowest point, the roller shall

keep a certain distance with the mechanical arm. (as shown by

the arrow in figure 2).

Adjustment of the third mechanical hand

1. Please refer to the second mechanical hand for adjustment.

Page 19 of 39

Adjustment of the fourth mechanical hand

1. Adjust the eccentric shaft on the internal and external mechanical

arms to make the two mechanical arms vertically at the center of the

cup seat (refer to the adjustment of the first mechanical hand

for details). Adjust the internal and external mechanical claws to

make the interval between the internal and external mechanical

claws at about 0.8mm.

2. Adjust the internal and external mechanical claws to make the

internal mechanical claw be about 0.5-1mm lower than the external

mechanical claw (refer to the black arrow indicated in the following

figure 1).

3. Adjust the height of the insertion board. When the insertion board

descends to the lowest point, make the folding shaft at the center of

the internal mechanical claw (refer to the white arrow indicated in

the following figure 2).

Page 20 of 39

Adjustment of the fifth mechanical hand

1. Adjust the eccentric shaft on the internal and external mechanical

arms to make the two mechanical arms vertically at the center of the

cup seat (refer to the adjustment of the first mechanical hand

for details). The clarity of the printed code granules can be adjusted

by M6 screws on the internal and external mechanical arms.

Page 21 of 39

Page 22 of 39

9. Adjustment of Automatic Tube Feeding System

923

3

20

6 19

13

15

16

18

17

12

14

218

7

1

5

9

10 11

22

2

4

1

2

3

4

5

6

7

8

Schematic Figure of Tube Feeding Part

Page 23 of 39

1. Tube bucket 2. Rotary shaft 3. Locking

handle

4. Right fender of

tube bucket 5. Pentagonal nut

6. Handle 7. M8 screw 8. Left support 9. Stainless steel

turning plate

10. Adjustable side

fender

11. Adjustable

fender 12. Joint bearing 13. Pull rod 14. Turning plate

15. Retaining plate

of turning plate

16. Turning plate

base

17. Tube feeding

fender of turning

plate

18. M8 screw 19. Right support

nut 20. Linear bearing

21. Right support 22. SI32*65 cylinder23. Tube fender

support

○1 . Basic adjustment of integral height

Loosen screws 7 and 18, turn handle 6 to adjust the integral height

to the required one, which shall make that the turning plate of the

tube feeding device shall be 10-20mm away from the cup seat at its

bottom when the turning plate turns upwards at an angle of 90°.

○2 . Tube feeding device

Change a suitable turning plate, adjust retaining plate of turning

plate 15 to achieve different heights and adjust turning plate base 16

to achieve different angles.

○3 . Adjustment of height of tube feeding bottom board

According to the height of turning plate, adjust the two screws at

○3 , so as to make the tube feeding bottom board be 3-5mm

Page 24 of 39

higher than turning plate.

○4 . Forward and backward adjustment of tube feeding bottom board

According to the position of turning plate, adjust the two screws at

○4 , so as to make the tube feeding bottom board be 3-5mm away

from the center of turning plate.

○5 . Adjustment of adjustable fender

According to the size of the tube, adjust the height of adjustable

side fenders 10 and adjustable fender 11 and make the height 5mm

higher than that of the tube.

○6 . Adjustment of stainless steel fender

The fender is 5mm higher than the tube and its angle is about

vertical to the tube feeding bottom board.

○7 . Adjustment of tube bucket outlet

Adjust the height of fender 4 to make the outlet be within the height

of 2-4 layers of tubes.

○8 . Adjustment of tube feeding

First lower the fender 4 and block the tube bucket outlet. Unpack

the packaging box for tubes and feed all the tubes in the box onto

the tube bucket. Loosen the locking handle 3 to make the tube

bucket 1 rotate backwards at a certain angle around the rotary shaft

2. Tighten the locking handle 3. Take out the packaging box. After

Page 25 of 39

the tubes are arranged in order, loosen the locking handle 3 and turn

the tube bucket forward. Tighten the locking handle 3 and open the

fender of tube outlet.

○9 . Adjustment of tube fender support

Turn the rotary table to the work station. Adjust the front and back

tube fender supports to make the tube fender supports keep a

distance of 5mm with the outside wall of the tube.

After the above 9 procedures are completed, manually put the tubes

into the tube feeding bottom board and carry out debugging again.

Before connecting with the air supply to carry out automatic

debugging for tube feeding, make sure that the tubes can be

smoothly inserted into the cup seats.

10. Adjustment of Transmission Part

1. Tension adjustment of transmission triangle belt

Loosen the fastening bolts at the motor base, and adjust the tension

of triangle belt to be appropriate and then tighten the nuts.

2. Tension adjustment of chain

Adjust the position of chain tension wheel to make the chain

tension appropriate.

3. Adjustment of safety clutch

If the spring pressure of safety clutch is too small, the clutch will be

Page 26 of 39

released and the machine can’t be normally started. Adjust the

adjusting nut for spring of clutch to minimize the spring pressure

which can make the machine normally started. In case of fault

overload, the clutch will be automatically released and the main

machine will stop its operation. The warning lamp will flash to give

indications. At the time, cut off the main power switch, and

eliminate the malfunction immediately. After the malfunction is

eliminated, hold the handle on the pulley and rock the pulley to

reset the clutch, and then restart the main machine according to the

starting procedures.

1、Screw the round nuts in for 8-15mm, with moderate overload

withstanding capacity. 2、When overloading occurs, the output shaft will be separated from the

clutch sprocket wheel, which will contact the switch and the machine will stop its operation.

Figure 10-1

Page 27 of 39

Schematic Figure of Transmission Part

1.Speedreducer pulley 2.Speed reducer 3. Output shaft 4. Steel ball 5. Clutch sprocket wheel

6. Copper cover 7. Pad 8. Compression spring 9. Pressure cover 10. Round nut

12. Disassembly and Cleaning

The disassembly procedures and cleaning requirements for parts needed to be

cleaned are described in this chapter.

1. Hopper

Loosen the hopper screws on the filling valve body and remove the

hopper. During the first time use, please clean the parts by using

solution made of edible detergent and then flush them with clear

Page 28 of 39

water, and finally scrub the internal wall with alcohol and make

them dry in the air.

2. Filling nozzle body and filling nozzle

Loosen the fastening screws on the filling head of filling valve

body and remove the air pipe to disassemble the filling head. Then

screw off the filling nozzle to clean the filling nozzle body and

filling nozzle with the cleaning method same as the above.

3. Filling valve body

Loosen the screws connecting the valve body and the cylinder to

separate the valve body from the cylinder. Loosen the rapid

installation ferrule of the valve body and remove the filling valve.

Gently push out the spool shaft, and carry out the cleaning with the

method same as the above.

4. Note: When removing the valve body and spool shaft, please do not

damage the valve spool and collide with the internal cavity of valve.

13. Daily Maintenance

1. Machine body

After work of each shift, the workers shall cut off the power supply,

clean and wipe the filling nozzles, cup seats, rotary table, sealing

and code printing clamp mouths with absorbent cotton dipped into

medicinal alcohol to maintain all parts clean without dusts. Then,

close the reinforced organic glass door.

2. Sealing part

Page 29 of 39

The roller bearing on the mechanical arm and the radial ball

bearing of supporting clamp rod shall be added with lubricating

grease once every three months.

3. Scale structure

The lubricating grease of the large table column bushing and scale

structure shall be replaced once half a year and they shall be

checked and oiled once a week.

4. Speed reducer

Check once a week. If the oil level is lower than 1/2 of that as

shown on the window, if it is lower than 1/2, please add 30# engine

oil in time.

5. The main drive system, chain and cam plate located at the bottom of

the machine table shall be checked and oiled once a week.

6. If the machine is not used for a long time, before restarting the

machine, please check if the screws of all parts are loose, and

tighten and adjust them if necessary. Check the lubricating

conditions of all transmission parts. After all the inspections are

completed, start the main machine according to the starting

procedures.

7. Please refer to the following figure for the servicing and lubricating

of the machine.

Page 30 of 39

Page 31 of 39

14. Common Malfunctions and Troubleshooting

Malfunctions Troubleshooting

1. Check if the safety emergency stop switch is locked.

2. Check if the air supply switch is on. The cylinder has no action.

3. Check if the single-direction signal valve is damaged.

1. Check the angle and distance between the photoelectric detector and the aluminum tube.

2. Adjust the sensibility of the photoelectric detector switch to be appropriate.

The code alignment and detection of the aluminum tube are incorrect.

3. Check if the photoelectric detector switch is damaged. If damaged, replace the photoelectric detector switch.

1. Check if the flow control valve is closed.

2. Check if the rotary filling valve is opened.

3. Check if the hopper is provided with sufficient materials.

The filling volume is inaccurate or there is no material discharging.

4. Check if all the connection places are sealed.

1. Check if the installation method of code granules is correct and if they are fastened.

The printed codes are not clear. 2. The code granules are worn. Replace the code granules.

Page 32 of 39

Pneumatic Drawing:

PLC Wiring:

Page 33 of 39

Page 34 of 39

Main Circuit Wiring Drawing:

Page 35 of 39

Packing List of IMC-60B Automatic Aluminum Tube Filling & Sealing Machine

No. Category Name Unit Piece Specification Remark

1 Main machine Set 1

2 Use instructions Copy 1

3 Product certification Copy 1

4 Packing list Copy 1

5

Technical documents Acceptance form of

installation and debuggingCopy 1

6 Cup seat Piece 9

7 Hopper Piece 1

8 Tube bucket Piece 1

9 Plunger pump Piece 1 Purchased by

customer

10 Heating box Piece 1 Purchased by

customer

11 Blender Piece 1

Purchased by

customer

12 Ultrasonic wave Piece 1

Purchased by

customer

13 Toolbox Piece 1

14 Seal ring Set 1

15 Dead wrench Piece 4

16 Flexible wrench Piece 1

17 Slotted screwdriver,

Philips screwdriver Piece

1 for

each

18 Inner hexagon wrench Set 1

19 Code granules Set 1

20

Accessories

Grease gun Piece 1

Page 36 of 39

Inspector Packer Date of packing

IMC-60B Automatic Aluminum Tube Filling &

Sealing Machine

M a c h i n e m o d e l IMC-60B

M a c h i n e N o .

E x - f a c t o r y d a t e

D a t e o f p u r c h a s i n g

A c c e p t a n c e

s u g g e s t i o n o f u s e r

U n i t s e a l o f u s e r

U s e r ’ s a d d r e s s

R e s p o n s i b l e p e r s o n

o f u s e r

C o n t a c t p h o n e o f

u s e r

P C

S u p p l i e r

Page 37 of 39

Note: After the product is inspected as qualified, the customer shall fill in

the “acceptance form of RGZF-60B automatic aluminum tube filling &

sealing machine” and send (fax) it back to the customer service center of

our company for record. If it is not sent back, it will be deemed as waiver

of guaranteed maintenance.

Page 38 of 39

Lobe Pump

Manual Operation

Product Certification

Product name: Automatic aluminum tube filling & sealing machine

Product model: IMC-60B

Ex-factory No.:

The product has been inspected as qualified

And is allowed to leave the factory.

Inspector:

Date of inspection: