CLEALL ANDREW (GB)
| Claims 1. An apparatus for filling a material into a receptacle, said apparatus comprising: (i) a material reservoir for containing an amount of the material to be filled and a filling station adjacent the material reservoir; (ii) a receptacle handling unit comprising a pair of axially aligned bushes for collecting a receptacle from a receptacle reservoir, wherein the receptacle comprises a receptacle body and receptacle closure; and (iii) a bush pair handling system comprising: (a) a means for separating the receptacle into a receptacle body and a receptacle closure, said means comprising a pair of mating bushes provided with axially aligned bores, wherein the mating bushes are capable of independently handling the receptacle body and receptacle closure by being separated into a body bush and closure bush; (b) means for temporarily attaching and detaching the one or both of the bushes from the bush pair handling system; (c) means for transporting the receptacle body to the filling station and aligning the receptacle body with a filler nozzle at the filling station; (d) means for transporting the filled receptacle body from the filling station to a closure unit for refitting the receptacle closure; and e) means for segregating compliant receptacles from non-compliant receptacles. 2. Apparatus according to claim 1 wherein the material to be filled into the receptacle is a liquid or a solid particulate material. 3. Apparatus according to claims 1 or 2 wherein the material to be filled into the receptacle is a solid particulate material. 4. Apparatus according to claim 3 wherein the material to be filled into the receptacle is a solid particulate material in the form of powder, granules or pellets. 5. Apparatus according to any one of the preceding claims wherein the material to be filled into the receptacle is a pharmaceutical material. 6. Apparatus according to any one of the preceding claims wherein the receptacle is a gelatin capsule. 7. Apparatus according to any one of the preceding claims wherein the dose of material to be filled into the receptacle is measured gravimetrically or volumetrically. 8. Apparatus according to claim 7 wherein the dose of material to be filled into the receptacle is measured gravimetrically. 9. Apparatus according to claim 8 wherein the dose of material to be filled into the receptacle is measured using real time weight control. 10. Apparatus according to claim 9 wherein the dose of material to be filled into the receptacle is measured using a Fill2Weight™ process described in European Patent application No. 2590862 (WO 2012/004606). 11. Apparatus according to any one of the preceding claims wherein the pair of mating bushes comprises a male bush and a female bush. 12. Apparatus according to claim 11 wherein the male bush is the body bush and the female bush is the closure bush. 13. Apparatus according to any one of the preceding claims wherein the means for segregating compliant receptacles from non-compliant receptacles comprises positioning the filled receptacle (in its body bush) on a weigh cell. 14. Apparatus according to claim 13 wherein the weigh cell is capable of determining whether a receptacle is compliant or non-compliant; and transporting the body bush containing the receptacle adjacent to a respective hopper where the receptacle is ejected from the body bush into a compliance hopper or non-compliance hopper as appropriate. 15. Apparatus according to any one of the preceding claims wherein the body bush that is temporarily attached and/ or detached from the bush pair handling system. 16. Apparatus according to any one of the preceding claims wherein the apparatus for filling a material into a receptacle is in combination with a material doser for accurately filling material into a receptacle; the material doser comprising a hopper with a tip having an aperture through which powder may flow, a closure to close the aperture and a vibration device configured to agitate the hopper, wherein a first portion of the hopper is formed of flexible material and a second portion proximate the tip is formed of substantially rigid material. 17. Apparatus according to any one of the preceding claims wherein the means for transporting the receptacle to and from a filling station is automated. 18. Apparatus according to claim 17 wherein the means for transporting the receptacle to and from a filling station comprises a robotic arm which is remotely controlled and/ or computer controlled. 19. Apparatus according to claim 18 wherein the robotic arm is provided with at least one bush holder which is aligned with at least one receptacle holder, such that, the bush holder and the receptacle holder are capable of being separated, in order to open the receptacle and/or re-associated enabling the receptacle to be reclosed. 20. Apparatus according to any one of the preceding claims wherein the bush comprises a low friction material. 21. Apparatus according to any one of the preceding claims wherein the robotic arm is provided with a plurality of bush holders and receptacle holders. 22. Apparatus according to any one of the preceding claims wherein the robotic arm is provided with a rotatory shaft rotatably connected to an extension arm, such that the extension arm is provided with a bush pair holder and receptacle holder at each end. 23. Apparatus according to claim 22 wherein one or both of the bushes that make up the bush pair can be automatically separated from the extension arm. 24. Apparatus according to claim 23 wherein once bushes have been separated concurrent processing of the receptacle parts can be carried out. 25. Apparatus according to claim 22 wherein the robotic arm is provided with a pair of bush pair holders and receptacle holders. 26. Apparatus according to claim 25 wherein the robotic arm is provided with a plurality of bush pair holders and receptacle holders. 27. Apparatus according to any one of claims 18 to 26 wherein the robotic arm is capable of visiting more than one filling site. 28. Apparatus according to claim 27 wherein the material comprises a combination therapy comprising more than one active ingredient. 29. Apparatus according to claim 28 wherein the material comprises a combination therapy comprising more than one active ingredient. 30. Apparatus according to any one of the preceding claims wherein the body bush is designed to be only loosely held in the bush pair holder so that the body bush may be moved longitudinally whilst being retained in the bush pair holder. 31. Apparatus according to claim 30 wherein the bush holder is located at the end of the extension arm and comprise a fork capable of being located about the bush. 32. Apparatus according to claim 31 wherein the bush comprises a bush body and is provided with a circumferential shoulder. 33. Apparatus according to any one of the preceding claims wherein each of the bush and the receptacle holder is provided with a corresponding chamfered surface, so that the bush and the receptacle holder can meet in a male/female arrangement. 34. Apparatus according to any one of the preceding claims wherein the body bush is designed to be held in the bush pair holder so that the body bush may be moved longitudinally whilst being retained in the bush pair holder. 35. Apparatus according to claim 34 wherein the bush pair holder is adapted to hold the body bush by means of a pneumatic vacuum cup, a vacuum shoe, a pneumatic gripper, an electric gripper or a magnet. 36. Apparatus according to any one of the preceding claims wherein a weighing system is included so that the receptacle can be weighed prior to being filled. 37. Apparatus according to claim 36 wherein a control system is included and is configured to operate the material dispenser only when the correct weight of receptacle is detected. 38. Apparatus according to any one of claims 18 to 37 wherein the robotic arm is provided with a closure plate mounted adjacent or above the receptacle holder, which facilitates the closure of the respectable after filling, providing a surface against which the receptacle closure can be abutted during re-closure of the receptacle. 39. The use of an apparatus for filling a material into a receptacle, said apparatus comprising: (i) a material reservoir for containing an amount of the material to be filled and a filling station adjacent the material reservoir; (ii) a receptacle handling unit comprising a pair of axially aligned bushes for collecting a receptacle from a receptacle reservoir, wherein the receptacle comprises a receptacle body and receptacle closure; and (iii) a bush pair handling system comprising: (a) a means for separating the receptacle into a receptacle body and a receptacle closure, said means comprising a pair of mating bushes provided with axially aligned bores, wherein the mating bushes are capable of independently handling the receptacle body and receptacle closure by being separated into a body bush and closure bush; (b) means for temporarily attaching and detaching the one or both of the bushes from the bush pair handling system; (c) means for transporting the receptacle body to the filling station and aligning the receptacle body with a filler nozzle at the filling station; (d) means for transporting the filled receptacle body from the filling station to a closure unit for refitting the receptacle closure; and e) means for segregating compliant receptacles from non-compliant receptacles. 40. The use according to claim 39 wherein the material to be filled into the receptacle is a liquid or a solid particulate material. 41. The use according to claims 39 or 40 wherein the material to be filled into the receptacle is a solid particulate material. 42. The use according to claim 41 wherein the material to be filled into the receptacle is a solid particulate material in the form of powder, granules or pellets. 43. The use according to any one of claims 39 to 42 wherein the material to be filled into the receptacle is a pharmaceutical material. 44. The use according to any one of claims 39 to 43 wherein the receptacle is a gelatin capsule. 45. The use according to any one of claims 39 to 44 wherein the dose of material to be filled into the receptacle is measured gravimetrically or volumetrically. 46. The use according to claim 45 wherein the dose of material to be filled into the receptacle is measured gravimetrically. 47. The use according to claim 46 wherein the dose of material to be filled into the receptacle is measured using real time weight control. 48. The use according to claim 47 wherein the dose of material to be filled into the receptacle is measured using a Fill2Weight™ process described in European Patent application No. 2590862 (WO 2012/004606). 49. The use according to any one of claims 39 to 48 wherein the pair of mating bushes comprises a male bush and a female bush. 50. The use according to claim 49 wherein the male bush is the body bush and the female bush is the closure bush. 51. The use according to any one of claims 39 to 50 wherein the means for segregating compliant receptacles from non-compliant receptacles comprises positioning the filled receptacle (in its body bush) on a weigh cell. 52. The use according to claim 51 wherein the weigh cell is capable of determining whether a receptacle is compliant or non-compliant; and transporting the body bush containing the receptacle adjacent to a respective hopper where the receptacle is ejected from the body bush into a compliance hopper or non-compliance hopper as appropriate. 53. The use according to any one of claims 39 to 52 wherein the body bush that is temporarily attached and/ or detached from the bush pair handling system. 54. The use according to any one of claims 39 to 53 wherein the apparatus for filling a material into a receptacle is in combination with a material filler for accurately filling material into a receptacle; the material doser comprising a hopper with a tip having an aperture through which powder may flow, a closure to close the aperture and a vibration device configured to agitate the hopper, wherein a first portion of the hopper is formed of flexible material and a second portion proximate the tip is formed of substantially rigid material. 55. The use according to any one of claims 39 to 54 wherein the means for transporting the receptacle to and from a filling station is automated. 56. The use according to claim 55 wherein the means for transporting the receptacle to and from a filling station comprises a robotic arm which is remotely controlled and/ or computer controlled. 57. The use according to claim 56 wherein the robotic arm is provided with at least one bush holder which is aligned with at least one receptacle holder, such that, the bush holder and the receptacle holder are capable of being separated, in order to open the receptacle and/or re-associated enabling the receptacle to be reclosed. 58. The use according to any one of claims 39 to 57 wherein the bush comprises a low friction material. 59. The use according to claim 39 wherein the robotic arm is provided with a plurality of bush holders and receptacle holders. 60. The use according to any one of claims 39 to 59 wherein the robotic arm is provided with a rotatory shaft rotatably connected to an extension arm, such that the extension arm is provided with a bush holder and receptacle holder at each end. 61. The use according to claim 60 where one or both of the bushes that make up the bush pair can automatically be separated from the extension arm. 62. The use according to claim 61 where once bushes have been separated concurrent processing of the receptacle parts can be carried out. 63. The use according to claim 60 wherein the robotic arm is provided with a pair of bush holders and receptacle holders. 64. The use according to claim 63 wherein the robotic arm is provided with a plurality of pairs of bush holders and receptacle holders. 65. The use according to any one of claims 56 to 64 wherein the robotic arm is capable of visiting more than one filling site. 66. The use according to claim 65 wherein the material comprises a combination therapy comprising more than one active ingredient. 67. The use according to claim 66 wherein the material comprises a combination therapy comprising more than one active ingredient. 68. The use according to any one of claims 39 to 67 wherein the bush is designed to be only loosely held in the bush holder so that the bush may be moved longitudinally whilst being retained in the bush holder. 69. The use according to claim 68 wherein the bush holder is located at the end of the extension arm and comprise a fork capable of being located about the puck. 70. The use according to claim 69 wherein the puck comprises a puck body and is provided with a circumferential shoulder. 71. The use according to any one of claims 39 to 70 wherein each of the puck and the receptacle holder is provided with a corresponding chamfered surface, so that the puck and the receptacle holder can meet in a male/female arrangement. 72. The use according to any one of claims 39 to 71 wherein the body bush is designed to be held in the bush pair holder so that the body bush may be moved longitudinally whilst being retained in the bush pair holder. 73. The use according to claim 72 wherein the bush pair holder is adapted to hold the body bush by means of a pneumatic vacuum cup, a vacuum shoe, a pneumatic gripper, an electric gripper or a magnet. 74. The use according to any one of claims 39 to 73 wherein a weighing system is included so that the receptacle can be weighed prior to being filled. 75. The use according to claim 74 wherein a control system is included and is configured to operate the material dispenser only when the correct weight of receptacle is detected. 76. The use according to any one of claims 56 to 75 wherein the robot is provided with a closure plate mounted adjacent or above the receptacle holder, which facilitates the closure of the respectable after filling, providing a surface against which the puck and receptacle holder can be abutted during re-closure of the receptacle. 77. A method of filling a receptacle with a consistent dose of a material, wherein the method comprises the steps of (i) filling a reservoir with an amount of material (ii) operating a receptacle handling unit comprising a receptacle bush pair, to collect a receptacle from a receptacle reservoir; and (iii) separating the receptacle into two parts and means for transporting one part of the receptacle to a filling station filling station adjacent the material reservoir; (iv) aligning the receptacle with a filler nozzle; (v) filling the receptacle with the material; (vi) transporting the filled receptacle from the filling station to a unit for reclosing the receptacle closure; and (vii) means for dispensing the filled receptacle from the bush. 78. The method according to claim 77 wherein the material to be filled into the receptacle is a liquid or a solid particulate material. 79. The method according to claims 77 or 78 wherein the material to be filled into the receptacle is a solid particulate material. 80. The method according to claim 79 wherein the material to be filled into the receptacle is a solid particulate material in the form of powder, granules or pellets. 81. The method according to any one of claims 77 to 79 wherein the material to be filled into the receptacle is a pharmaceutical material. 82. The method according to any one of claims 77 to 81 wherein the receptacle is a gelatin capsule. 83. The method according to any one of claims 77 to 82 wherein the dose of material to be filled into the receptacle is measured gravimetrically or volumetrically. 84. The method according to claim 83 wherein the dose of material to be filled into the receptacle is measured gravimetrically. 85. The method according to claim 84 wherein the dose of material to be filled into the receptacle is measured using real time weight control. 86. The method according to claim 85 wherein the dose of material to be filled into the receptacle is measured using a Fill2 Weight™ process described in European Patent application No. 2590862 (WO 2012/004606). 87. The method according to any one of claims 77 to 86 wherein the pair of mating bushes comprises a male bush and a female bush. 88. The method according to claim 87 wherein the male bush is the body bush and the female bush is the closure bush. 89. The method according to any one of claims 77 to 89 wherein the means for segregating compliant receptacles from non-compliant receptacles comprises positioning the filled receptacle (in its body bush) on a weigh cell. 90. The method according to claim 89 wherein the weigh cell is capable of determining whether a receptacle is compliant or non-compliant; and transporting the body bush containing the receptacle adjacent to a respective hopper where the receptacle is ejected from the body bush into a compliance hopper or non-compliance hopper as appropriate. 91. The method according to any one of claims 77 to 90 wherein the body bush that is temporarily attached and/ or detached from the bush pair handling system. 92. The method according to any one of claims 77 to 91 wherein the apparatus for filling a material into a receptacle is in combination with a material doser for accurately filling material into a receptacle; the material doser comprising a hopper with a tip having an aperture through which powder may flow, a closure to close the aperture and a vibration device configured to agitate the hopper, wherein a first portion of the hopper is formed of flexible material and a second portion proximate the tip is formed of substantially rigid material. 93. The method according to any one of claims 77 to 92 wherein the means for transporting the receptacle to and from a filling station is automated. 94. The method according to claim 93 wherein the means for transporting the receptacle to and from a filling station comprises a robotic arm which is remotely controlled and/ or computer controlled. 95. The method according to claim 94 wherein the robotic arm is provided with at least one puck holder which is aligned with at least one receptacle holder, such that, the puck holder and the receptacle holder are capable of being separated, in order to open the receptacle and/or re-associated enabling the receptacle to be reclosed. 96. The method according to any one of claims 77 to 95 wherein the puck comprises a low friction material. 97. The method according to any one of claims 77 to 96 wherein the robotic arm is provided with a plurality of puck holders and receptacle holders. 98. The method according to any one of claims 77 to 97 wherein the robotic arm is provided with a rotatory shaft rotatably connected to an extension arm, such that the extension arm is provided with a puck holder and receptacle holder at each end. 99. The method according to claim 98 where one or both of the bushes that make up the bush pair can automatically be separated from the extension arm. 100. The method according to claim 99 where once bushes have been separated concurrent processing of the receptacle parts can be carried out. 101. The method according to claim 98 wherein the robotic arm is provided with a pair of puck holders and receptacle holders. 102. The method according to claim 101 wherein the robotic arm is provided with a plurality of pairs of puck holders and receptacle holders. 103. The method according to any one of claims 94 to 102 wherein the robotic arm is capable of visiting more than one filling site. 104. The method according to claim 103 wherein the material comprises a combination therapy comprising more than one active ingredient. 105. The method according to claim 104 wherein the material comprises a combination therapy comprising more than one active ingredient. 106. The method according to any one of claims 77 to 105 wherein the puck is designed to be only loosely held in the puck holder so that the puck may be moved longitudinally whilst being retained in the puck holder. 107. The method according to claim 106 wherein the puck holder is located at the end of the extension arm and comprise a fork capable of being located about the puck. 108. The method according to claim 107 wherein the puck comprises a puck body and is provided with a circumferential shoulder. 109. The method according to any one of claims 77 to 108 wherein each of the puck and the receptacle holder is provided with a corresponding chamfered surface, so that the puck and the receptacle holder can meet in a male/female arrangement. 110. The method according to any one of claims 77 to 109 wherein the body bush is designed to be held in the bush pair holder so that the body bush may be moved longitudinally whilst being retained in the bush pair holder. 111. The method according to claim 110 wherein the bush pair holder is adapted to hold the body bush by means of a pneumatic vacuum cup, a vacuum shoe, a pneumatic gripper, an electric gripper or a magnet. 113. The method according to any one of claims 77 to 111 wherein a weighing system is included so that the receptacle can be weighed prior to being filled. 114. The method according to claim 113 wherein a control system is included and is configured to operate the material dispenser only when the correct weight of receptacle is detected. 115. The method according to any one of claims 94 to 114 wherein the robot is provided with a closure plate mounted adjacent or above the receptacle holder, which facilitates the closure of the respectable after filling, providing a surface against which the receptacle can be abutted during re-closure of the receptacle. 116. Apparatus, use or method as hereinbefore described with reference to the accompanying description and figures. |
Field of the Invention
The present invention relates to apparatus and methods for filling of liquid or solid particulate materials into receptacles.
More particularly, the present invention relates to apparatus for filling pharmaceutical dosage forms, such as, soft or hard gelatin capsules, with pharmaceutically active formulations, usually in the form of liquid or solid particulate materials, e.g. powders, granules or pellets, especially for use as pharmaceuticals. The present invention also relates to methods related thereto.
Background to the Invention
Capsule filling machines or encapsulation machines are commonly used, especially in the pharmaceutical industry, for filling empty soft or hard gelatin capsules with pharmaceutical formulations. Such pharmaceutical formulations may be in the form of solid particulate materials, such as powders, granules, pellets and the like.
Hard or soft gelatin capsules generally comprise two parts, a body and a cap. Capsule filling machines usually operate by first separation the caps from bodies; filling a volumetrically measured dose of the formulation into the separated body of the capsule of the gelatin capsules; re-joining the capsules, i.e. conjoining the capsule cap and body; and then ejection of the filled capsule from the capsule filling machines. In addition, automated capsule filling machines will usually also comprise the ability to reject bad gelatin capsules, i.e. capsules which are broken or which are not paired, i.e. do not comprise a body and a cap.
Manual, hand operated capsule filling machines are known and are generally used in hospitals or pharmacies.
In the manufacture of pharmaceuticals, automated capsule filling machines are widely used. Modern capsule filling machines generally comprise a rotary carousel equipped with a plurality of operating stations for processing the capsules.
The filling method usually consists of the steps opening the empty capsules at a station where the capsule bodies are separated from the caps to form two separate rows of bodies and caps; filling a volumetrically metered quantity of the pharmaceutical formulation into each capsule body at a filling station; and closing each filled capsule by applying a cap to the respective body.
US Patent No. 3,847,191 describes the dispensing of metered amounts of material by compressing the powder material, typically by application of a vacuum in a trough, followed by insertion of a filling gun within the compacted material to gather an amount of the compacted material followed in turn by dispensing such amount in a respective capsule.
However, such machines generally suffer from dose variation in the receptacles, particularly when filling a wide range of solid products having a wide range of packing densities and/or physical characteristics making handling difficult, such as shear sensitive materials. Consequently, this may cause capsules being filled with different amounts of a formulation. This is particularly undesirable when the capsules are filled with dose sensitive pharmaceutical formulations that must be administered at a precise predetermined dose.
US Patent No. 7,677,016, attempts to solve some of the above problems by volumetric measurements made during the filling step and by weighing capsules after they have been filled. However, such systems do not address the problem of dose variation that may occur during the filling step.
Therefore there still remains a need for a new apparatus and process for accurate and consistent filling of receptacles with a wide range of liquid or solid fill materials.
Summary of the Invention
We have now found a device that overcomes or mitigates the problems associated with the prior art devices. More particularly, the present invention provides a receptacle filling system which provides accurate real time weight control of the material being filled into the receptacle.
Thus, according to a first aspect of the present invention there is provided an apparatus for filling a material into a receptacle, said apparatus comprising:
(i) a material reservoir for containing an amount of the material to be filled and a filling station adjacent the material reservoir; (ii) a receptacle handling unit comprising a pair of axially aligned bushes for collecting a receptacle from a receptacle reservoir, wherein the receptacle comprises a receptacle body and receptacle closure; and
(iii) a bush pair handling system comprising:
(a) a means for separating the receptacle into a receptacle body and a receptacle closure, said means comprising a pair of mating bushes provided with axially aligned bores, wherein the mating bushes are capable of independently handling the receptacle body and receptacle closure by being separated into a body bush and closure bush;
(b) means for temporarily attaching and detaching the one or both of the bushes from the bush pair handling system;
(c) means for transporting the receptacle body to the filling station and aligning the receptacle body with a filler nozzle at the filling station;
(d) means for transporting the filled receptacle body from the filling station to a closure unit for refitting the receptacle closure; and e) means for segregating compliant receptacles from non-compliant receptacles.
The pair of mating bushes will generally comprise a male bush and a female bush. In a preferred aspect of the invention the male bush is the body bush and the female bush is the closure bush.
The means for segregating compliant receptacles, e.g. accurately filled receptacles, from non-compliant receptacles, e.g. damaged or inaccurately filled receptacles, will generally comprise positioning the filled receptacle (in its body bush) on a weigh cell, capable of determining whether a receptacle is compliant or non-compliant; and transporting the body bush containing the receptacle adjacent to a respective hopper where the receptacle is ejected from the body bush into a compliance hopper or non- compliance hopper as appropriate. Means for ejecting the receptacle from the body bush may comprise one or more ejections posts, such that the body bush can be depressed against the one or more ejections posts, urging the receptacle from body bush.
In one aspect of the invention it is preferred that it is the body bush that is temporarily attached and/ or detached from the bush pair handling system.
The material to be filled into the receptacle may be a liquid or a solid particulate material, e.g. in the form of powder, granules, pellets and the like. The material may also be combinations of forms of solid or liquid materials. The material may especially comprise a pharmaceutical material. It will be understood that the filling station may measure a dose of material to be filled into the receptacle gravimetrically or volumetrically, depending, inter alia, upon the nature of the material, etc. In one particular aspect of the invention the filling station measures the dose gravimetrically, for example, using real time weight control, such as the Fill2 Weight™ process described in European Patent application No. 2590862 (WO 2012/004606).
Thus, according to this aspect of the invention there is provided an apparatus for filling a material into a receptacle, as herein described, in combination with a material filler for accurately filling particulate material, for example a pharmaceutical substance, into a receptacle, the material doser comprising a hopper with a tip having an aperture through which powder may flow, a closure to close the aperture and a vibration device configured to agitate the hopper, wherein a first portion of the hopper is formed of flexible material and a second portion proximate the tip is formed of substantially rigid material.
Desirably, the means transporting the receptacle to and from a filling station is automated, for example, the means may comprise a robotic arm which may be remotely controlled and/ or computer controlled. Such a robotic arm will be provided with at least one bush pair holder which is aligned with at least one bush pair, such that, the bush pair is capable of being separated in order to open the receptacle and/or re-associated enabling the receptacle to be reclosed. If the receptacle is a conventionally known gelatin capsule, then the body of the capsule will be retained in the body bush and the cap or closure of the capsule will be retained in the closure bush, which remains fixed to the receptacle holder. Although it will be understood that it is within the scope of the present invention for the body of the capsule to be retained in closure bush and the cap retained in the body bush.
The bushes may comprise a low friction material, such as a thermoplastic polyethylene, e.g. UHMWPE or a low friction coated material
In a further embodiment, the robotic arm may be provided with a plurality of bush pair holders and bush pairs. In a particular embodiment the robotic arm may be provided with a rotatory shaft rotatably connected to an extension arm, such that the extension arm is provided with a bush holder and receptacle holder at each end. Thus, the robotic arm may be provided with a pair of bush holders and receptacle holders or a plurality of pairs of bush holders and receptacle holders, e.g. 4, 6, 8, 10, or more bush holders and two part bush assemblies.
When the robotic arm is provided with one or more pairs of bush holders and receptacle holders the rotatable extension arm can be rotated about the shaft, providing dual bush exchange or dual receptacle filling, thus allowing parallel processing of the receptacle. This significantly speeds the filling process allowing filling rates of from about 100 to about 1,000 receptacles per hour to be filled.
Increasingly, patients are required to take more than one medicine and this is especially the case in the treatment of bronchial disorders with respiratory drugs. For example, combination therapies such as a steroid with a P2 agonist, e.g. fluticasone and salmeterol, have been commercially successful. Therefore, according to a further aspect of the invention, the robotic arm may be capable of visiting more than one filling site. Such an arrangement is particularly advantageous when it is desired to fill a receptacle with a combination therapy comprising more than one active ingredient.
Desirably, the body bush is designed to be only loosely held in the bush pair holder so that the body bush may be moved longitudinally and axially whilst being retained in the bush holder. This enables the receptacle to be inserted in, closed or ejected, from the bush pair
Thus, in one embodiment the bush holder, for example, is located at the end of the extension arm, and may comprise a fork capable of being located about the body bush which allows the detachment of the bush from the extension arm. In this embodiment the bush pair comprises a bush body and is desirably provided with a circumferential shoulder, such that the fork at the end of the extension arm may wrap around the bush body and engage with the circumferential shoulder, enabling the bush to be located and lifted.
In a further embodiment the bush holder may be adapted to hold the body bush by means of a pneumatic vacuum cup, a vacuum shoe, gripper, a pneumatic gripper, an electric gripper or a magnet, as an alternative to the fork arrangement herein described, so that the body bush may be moved longitudinally whilst being retained in the bush pair holder.
In order to facilitate the alignment of the bush pair and the receptacle holder the and the opening and closing of the receptacle, the body bush and closure bush are provided with a corresponding chamfered surfaces, so that the bush and the receptacle holder can meet in a male/female arrangement.
According to an embodiment of the invention the receptacle and body bush may be weighed by a weighing system prior to being filled. This allows the system to determine whether a receptacle is present and/or whether a receptacle is damaged, for example if there is a hole in the capsule wall. A control system may be configured to operate the material dispenser only when the correct weight of receptacle is detected. In addition, the receptacle may be weighed by a weighing system during filling, this may enable the flow rate of the material dispenser to be altered during filling of the material, for example, the flow rate may be decreased as a predetermined target weight is approached. In addition, the robotic arm may also be provided with a closure plate, generally mounted adjacent or above the bush pair holder, which facilitates the closure of the respectable after filling, providing a surface against which the receptacle can be abutted during re-closure of the receptacle.
The receptacle will generally be a hard or soft gelatin capsule. The capsule will usually be resiliently deformable so that the capsule can be opened and re-closed after filling.
According to a further aspect of the invention there is provided the use of an apparatus herein described for filling a receptacle, such as a hard or soft gelatin capsule, with a consistent dose of material.
According to a yet further aspect of the present invention there is provided a method of filling a receptacle with a consistent dose of a material, wherein the method comprises the steps of
(i) filling a reservoir with an amount of material
(ii) operating a receptacle handling unit comprising a receptacle bush pair, to collect a receptacle from a receptacle reservoir; and
(iii) separating the receptacle into two parts and means for transporting one part of the receptacle to a filling station filling station adjacent the material reservoir;
(iv) aligning the receptacle with a filler nozzle; (v) filling the receptacle with the material;
(vi) transporting the filled receptacle from the filling station to a unit for reclosing the receptacle closure; and
(vii) means for dispensing the filled receptacle from the bush.
The invention will now be illustrated by way of example only and with reference to the accompanying figures in which:
Figures 1 is a cross-sectional view of the extension arm with bushes attached; and Figure 2 is schematic representation of the filling apparatus.
Referring to Figure 1, apparatus for filling a material into a receptacle comprises a robotic arm (1) operably linked to a robot wrist (2). The robotic arm (1) is adapted to rotate about a spindle (3). At each end (4 and 5) of the robotic arm (1) is located bush pair handling systems (6 and 7). Each of the bush pair handling systems (6 and 7) comprises a securely located closure bush (8 and 9) and a detachably located body bush (10 and 11). Closure bushes (8 and 9) rest in respective forks (12 and 13) in extension limbs (14 and 15).
Bush pair handling system (6) is in the “open” position, in which a receptacle (capsule) (16) is shown to be separated into a capsule body (16a) and a capsule closure (16b). The capsule body (16a) is located in the body bush (10) and the capsule closure (16b) is located in the closure bush (8).
Bush pair handling system (7) is in the “closed” position, in which a receptacle (capsule) (17) is shown as a conjoined unit. The body bush (11) and the closure bush (9) are shown having been brought together; the capsule (17) is closed and urged into the closure bush (9), ready for transfer to means for segregating compliant receptacles from non-compliant receptacles, e.g. a weigh cell (not shown).
Referring to Figure 2, apparatus for filling a material into a receptacle is shown comprising a robotic arm (1) connected to a robot (18). Between the robotic arm (1) and the robot (18) is a closure plate (19). Bush pair handling systems (6 and 7) are shown at the respective ends (4 and 5) of the robotic arm (1).
The apparatus is provided with a capsule dispenser (20) and a filling sy stem/ material dispenser (21). The capsule dispenser is provided with a detachment column (22), said column (22) being provided with a bush locator spindle (23). A weigh cell (24) is located adjacent the filling system/material dispenser (21), generally below the bush pair handling system (6).
A recoupling pillar (25) is also provided. The apparatus also includes ejection posts (26a and 26b) adjacent a pair of hoppers (27a and 27b) for dispatching compliant (27a) and non-compliant (27b) capsules (not shown).
In use the robotic arm (1) delivers a bush pair handling system (6) to a detachment column (22) of the capsule dispenser (21) and locates the closure bush (8) and body bush (10) about the bush locator spindle (23).
The capsule dispenser (21) dispenses a capsule (17) from the dispenser (21) into the bushes (8/10). The robotic arm 1 then depresses the bush (8/10) against the detachment column (22) urging the capsule closure (16b) into the corresponding closure bush (8), when pressure is released by the robotic arm (1), the closure bush (8) and the body bush (10) separate, leaving the capsule closure (16b) in the closure bush (8) and the capsule body (16a) in the body bush (10). The capsule body (16a) is then ready for filling.
The robotic arm (1) then collects the body bush (10) containing the capsule body (16a) and transfers it to the weigh cell (24) at the filling system/station (21). The capsule body (16a) is then filled to a gravimetrically predetermined amount and the robotic arm (1) retrieves the body bush (10) and delivers the body bush (10) and the closure bush (8) to the recoupling pillar (25). At the recoupling pillar (25) the robotic arm (1) depresses the bushes (8/10) between the recoupling pillar (25) and the closure plate (19). urging the body bush (10) and the closure bush (8) together, thus recoupling the capsule body(16a) and capsule closure (16b).
The robotic arm (1) then delivers the bushes (8/10) to one of the ejection posts (26a) or (26b), whereby the filled and recoupled capsule (17) is ejected into either the compliant hopper (27a) or non-compliant hopper (27b).
Providing a bush pair handling system (6 and 7) at each end (4 and 5) of the robotic arm (1) enables the robot (18) to continually process capsules, i.e. collecting another capsule whilst one capsule is being filled.