Automated Suppository Production and Turnkey Pharmaceutical Packaging Line Integration

IMA has introduced a fully integrated manufacturing and packaging line engineered to unify primary suppository processing with downstream secondary cartoning, labeling, and case packing. The automated technology suite targets high-throughput pharmaceutical manufacturing environments, establishing a continuous processing flow with synchronized serialization and aggregation across all packaging stages.

Continuous Primary Forming, Volumetric Filling, and Thermal Sealing
Primary container fabrication and liquid dosing are executed via the IMA Sarong SAAS 15 form-fill-seal system. The machine operates at speeds of up to 30,000 suppositories per hour, executing aluminum foil cavity forming, liquid product filling, and hermetic sealing within a continuous cycle.

The mechanical process forms cavities directly from packaging foil web stock, followed by volumetric dosing of the molten suppository formulation and continuous sealing. Thermal conditioning solidifies the filled dosage forms before the continuous strip is perforated and cut into programmed unit counts. Integrating these phases into a single platform minimizes mechanical handling between dosing and sealing, maintaining batch uniformity and reducing thermal degradation risks associated with transferring open product strips.



IMA complete suppository line

Downstream Cartoning and Tamper-Evident Labeling Mechanisms
Following primary packaging, suppository strips transfer directly to the IMA Safe A83 automatic cartoner. The cartoning station collates the multi-cavity strips, indexes them into product buckets, and synchronizes the insertion of pre-folded patient information leaflets into opened cartons before tuck or glue closure.

Once cartons are formed and closed, they pass to the IMA Life Sensitive AP400 labeling unit. This module applies optical vignette tax stamps and tamper-evident security labels across carton closure flaps. The automated application ensures physical container integrity and complies with global anti-tampering directives without introducing mechanical transit delays.



A83 carton closure

Flexible Secondary Packing and Supply Chain Serialization
Secondary transit packaging is handled by the IMA BFB CP18 MINIFLEX case packer, which automatically collates cartons and loads them into corrugated shipping cases. The system accommodates multiple case formats and pack patterns, adapting to variable secondary distribution and logistics standards.

Traceability architecture is embedded throughout the packaging train through the integration of an IMA Print and Apply system paired with Antares Vision inspection and software technologies. The system generates, applies, and optically verifies serialization identifiers at the individual carton stage, followed by hierarchical data aggregation at the shipping case stage. This multi-tier track-and-trace structure satisfies strict pharmaceutical serialization mandates and strengthens supply chain security against counterfeiting.



CP18 MINIFLEX

Single-Source Automation Architecture and Maintenance Workflow
Deploying a continuous production train from a single machinery manufacturer removes mechanical and electrical interface discrepancies common in multi-vendor integration. Communication protocols between the forming machine, cartoner, labeller, and case packer are standardized under a unified control environment.

The consolidated platform reduces project management overhead, minimizes commissioning intervals, and simplifies operator training. Routine maintenance routines, mechanical size changeovers, and parts inventories are harmonized across the line, providing predictable operational availability in high-volume pharmaceutical plants.



SENSITIVE AP400T tamper evident application

Additional Context:
This section details technical specifications and competitive benchmarking not included in the original product announcement

The IMA Sarong SAAS 15 utilizes cold-forming tooling for duplex (aluminum and polyethylene) or triplex laminates, processing reel widths up to 70 millimeters and reel diameters up to 490 millimeters. Filling volume ranges from 0.4 milliliters to 4.4 milliliters via positive displacement volumetric dosing pumps supplied by an 80-liter double-jacketed heated holding tank. Product solidification occurs inside integrated multi-stage spiral cooling chambers with filtered air circulation, requiring transit durations between 7 and 14 minutes depending on suppository lipid base viscosity.

Within the suppository processing and automated packaging sector, the primary mechanical benchmark for high-speed primary forming is the Farmo Res FARMO DUE FD-EVO series. The FD-EVO similarly achieves throughput ratings of up to 30,000 units per hour and employs modular construction separating forming, dosing, and cooling zones. However, standalone forming systems from dedicated thermoforming specialists typically require third-party integration with separate cartoning platforms (such as Uhlmann or Marchesini) and independent vision suppliers, necessitating complex line supervisory control and data acquisition (SCADA) middleware.

In contrast, IMA configures its suppository train as an integrated single-vendor line encompassing the SAAS 15 former, A83 cartoner, CP18 case packer, and factory-integrated Antares Vision serialization architecture. This turnkey approach eliminates external mechanical conveyor handoffs, aligns programmable logic controller communication buses, and standardizes validation protocols according to Good Automated Manufacturing Practice (GAMP 5) guidelines.

Edited by Natania Lyngdoh, Induportals editor, assisted by AI.

www.imagroup.com