ZANASI PLUS

MEDIUM-HIGH SPEED CAPSULE FILLING MACHINES

ZANASI PLUS WORKING CYCLE

ZANASI PLUS CAPSULE FILLING MACHINES

OFFER MAXIMUM VERSATILITY IN TERMS
OF THE COMBINED DOSING OF VARIOUS
PRODUCTS WITHIN THE SAME CAPSULE,
DEPENDING ON MACHINE CONFIGURATION
AND INSTALLED DOSING UNITS. THESE
MACHINES OFFER EASY ACCESS TO THE
WORK AREA, QUICK SIZE CHANGE-OVER
AND CLEANING TIME, AS WELL AS MAXIMUM
FLEXIBILITY.

THE WORK PARAMETERS OF THE MACHINE

CAN BE SEPARATELY ADJUSTED TO ALLOW
THE PROCESSING OF A WIDE RANGE OF
DIFFERENT PRODUCTS WITH EXCELLENT
RESULTS IN TERMS OF DOSING ACCURACY
AND SPEED.

OPERATOR FRIENDLINESS IS A HALLMARK

OF THESE MACHINES; THEIR SIMPLE
CONSTRUCTION AND ERGONOMIC
INTERFACE MEANS THAT SKILLED OPERATORS
ARE NOT REQUIRED TO RUN THESE
MACHINES.

1 2 3 4 5
CAPSULE INFEED AND AVAILABLE FOR SIZE PRODUCT DOSING
OPENING CHANGE-OVER OR
The capsules arriving from the infeed hopper CAPSULE PRESENCE
are accurately positioned and inserted into CHECKING
the bushings where the cap is removed from
This station is available to facilitate capsule size
the body by means of a vacuum.
change-over or to check capsule presence in
case a liquid dosing group is fitted.
On special request, this station can instead be
used for product dosing.
1 2 3

ALL ZANASI PLUS MODELS

ARE SUITABLE TO DOSE
ONE OR MORE PRODUCTS
INTO THE SAME CAPSULE
7 6 5 REACHING A SPEED OF
16,000, 48,000 AND 70,000
CAPSULES/HOUR.

6 7 8
UNOPENED CAPSULE CAPSULE CLOSING CAPSULE DISCHARGE AND
SELECTION AND REMOVAL The bushings containing the capsule bodies BUSHINGS CLEANING
Any unopened capsule is rejected by means re-align themselves with the corresponding Closed capsules are discharged by the
of appropriate pushers. On special request, capsule caps. The capsules are then closed combined action of pushers and compressed
this station can instead be used for product by appropriate pushers. air. A conveyor chute transports the capsules
dosing. towards the finished product container.
Upper and lower bushings are cleaned of any
residual dust by means of compressed air.
ZANASI PLUS DOSING UNITS

MICROTABLETS DOSING UNIT WITH

EXACT COUNTING AND CHECK
The unit is composed of:
- One wheel with a predefined number of holes, the dimensions of
which are dictated by the size of the microtablets.
- A drum with pushers to take the microtablets inside the capsule
bodies.
The microtablets enter into the wheel holes by means of a
vacuum and a brush eliminates the excess microtablets. The
wheel rotates, the vacuum is cut off and the microtablets
fall down into the drum. The product is then dosed into
the capsules by gravity fall with the help of pushers which
are particularly recommended in case of electrostaticity.
Available for Zanasi Plus 16 only.

This system allows the exact

number/count of microtablets
to be filled into each capsule.
An optional camera can even
be installed over the wheel to
double check the presence of the
microtablets.
POWDER DOSING UNIT PELLET/MICROTABLETS DOSING UNIT
Dosators are mounted on one block and are sited in two opposite Dosators are mounted on one block and are sited in two opposite
segments. segments.
1. The block moves down and the dosators on the first segment 1. The block moves down and the dosators on the first segment
penetrate the powder bed inside the product bowl, whilst the penetrate the powder bed inside the product bowl, whilst the
opposite ones are positioned above the capsule bodies. opposite ones are positioned above the capsule bodies.
2. The pistons of the first segment compress the powder forming slugs; 2. The pistons of the first segment create the dosing volume and
the opposite ones eject the powder slugs into the capsule bodies. vacuum force pellets to fill it; the opposite ones eject the pellets
3. The block moves up and turns; dosators with slugs are positioned into the capsule bodies, the vacuum is released.
over the next capsule bodies, whilst the empty ones are positioned 3. The block moves up and turns; the dosators filled with pellets are
over the product bowl and the cycle begins once more. positioned over the next capsule bodies, whilst the empty dosators are
positioned over the product bowl and the cycle begins once more.

In addition to the Excess pellets are

rotary bowl fitted on removed by a jet of
standard machines, the air. This system is
IMA patented vacuum particularly suitable
bowl can be supplied for for microtablets
powder pre-compacting and pellets with a
in case very fine powders delicate coating.
have to be dosed.

TABLET DOSING UNIT LIQUID DOSING UNIT

The unit can introduce one or more tablets into the capsule body The group uses an extremely precise volumetric dosing system
in one stroke, using a blade and suitably shaped feeding tubes. composed of a series of syringes, drawing liquid from the container
The filling phase is electronically monitored by a sensor which and pushing it into the capsule bodies, and a series of sliding valves
checks the tablet presence whilst dosing and the tablet absence connecting the syringes with the container or the outlet tubes.
upon blade return. The liquid container can be fitted with a mixer and a heating and
In case of any malfunction, the machine stops. temperature control system, so that thixotropic or heat sensitive
products can be dosed as well as oily substances.
ZANASI PLUS OPTIONALS

ZANASI THC IS AVAILABLE WHEN A HIGH CONTAINMENT CONFIGURATION IS REQUESTED

STATISTIC WEIGHT CHECK 100% IN-LINE NET WEIGHT CONTROL

AND SELF-ADJUSTMENT Zanasi Plus dosators can be fitted with strain gauges to perform
All Zanasi Plus machines are prearranged to be equipped with a 100% indirect net weight control of powder dosed, by measuring
statistic weight checking unit for production monitoring. The the compaction force. This system is integrated inside the machine
group is prepared for 21 CFR part 11 compliance. and allows a 100% check of product in-line and also to reject
If the machine is also equipped with self-adjustment, the weight of product out of specification.
the sampled capsules can be fed back to the control system which
automatically adjusts the position of the dosing head to keep the
set target weight. In this way production is automatically kept
within the parameters set by the operator.
ZANASI PLUS OPTIONALS AND TECHNICAL DATA

PELLET CONTROL WITH LVDT

An in-line volumetric control of product dosed can be fitted for
pellet dosing: the system features a set of pushers connected to
LVDT sensors, measuring the pellet volume inside the capsule.

◾◾ 100% of the production is controlled

◾◾ IN-LINE control of NET WEIGHT: no

influence of empty capsules weight
variations

◾◾ Single rejection of capsules out of limits

Pushers with LVDT sensors

1831
1796

1974
2077

2563
940
2563
940

1262

ZANASI PLUS 16 ZANASI PLUS 48 ZANASI PLUS 70

Maximum output (capsules/hour) 16,000 48,000 70,000
Number of capsules per cycle 2 6 9
Capsule size 000-5, supro A-E, DB, DBAA 00-5, supro A-E, DB, DBAA
Maximum installed power (kW) 8 14
Aspiration 3,200 litres/minute - 2,400 mm H2O 4,600 litres/minute - 3,100 mm H2O
Compressed air 100 dm3/min – 6 bar
Vacuum 100 m3/h – 3 mbar
Standard voltage 230/400 V (±10%) – 50/60 Hz
Weight (kg) 1,000 1,100 1,200
 October 2016 - 990ZZP2001
www.ima-pharma.com

IMA S.p.A. reserves the right to make any changes to the described machine characteristics.

IMA S.p.A.
IMA ACTIVE division
Via I° Maggio 14 - 40064 Ozzano Emilia (Bologna) - Italy
Tel. +39 051 6514111 - Fax +39 051 6514287
[email protected] - www.ima.it