No cotton-picking problem with poly headspace insert: a new system that inserts folded film tubing into tablet bottles offers protection, ease of use and promotional opportunities - Problem-Solving Case History - from Axon Corp

Food & Drug Packaging, April, 2003

IN A NUTSHELL

Goal: Replace tablet-bottle cotton/rayon with easier-to-handle material

How: Plastic film inserter

Results: High production efficiencies, low manufacturing costs

Pop open a new bottle of aspirin, or almost any pharmaceutical or nutraceutical container. Immediately, end users face the extra headache of digging stubborn puffs of cotton or rayon from the bottle's headspace.

Now, however, a first-of-its-kind system from Axon Corp. utilizing tubular plastic technology eliminates this "cotton-picking" headache. The system also delivers soothing benefits such as longer product shelf life, high production efficiencies, and the opportunity to preprint films with promotional information or coupons. In short, Axon's AI-60 and AI-120 Automatic Film Inserters are positioned to be an innovative prescription for replacing the pharmaceutical-nutraceutical industry's traditional cotton/rayon insertion machinery as well as less common hand-insertion operations.

Historically, natural cotton was the industry's solution to bouncing and breakage of tablets or capsules inside bottles. Cotton, however, is a hydrophilic (moisture-attracting) fiber, and high humidity causes premature degradation of pharmaceutical and nutraceutical products. To solve this, some makers manually insert hydrophobic plastic, but at a high cost due to its labor-intensive nature.

California-based Pharmavite LLC, the nationally recognized maker of Nature Made vitamins and minerals and Nature's Resource herbal products, has enjoyed high satisfaction with Axon's new system. Eager to add plastic inserts equipment to its production line, packaging manager Dean Maenaga says Pharmavite had searched for equipment inside and outside the U.S. Yet existing machinery, he says, "would've required extensive modifications to existing lines at a significant cost." In contrast, the footprint of Axon's new system is smaller than Pharmavite's old cotton/rayon machinery.

Most importantly, Axon's system is cleaner, meeting Pharmavite's need to satisfy its sizable Japanese market's preference for plastic inserts and solving complaints about stray cotton/rayon fibers that overlap bottle caps. "After being in Japan's market for years, now we've finally been able to provide them what consumers expect," reports Dan Murphy, Pharmavite's manager of package development.

Axon Sales Director Ed Farley says the technology was developed after Pharmavite asked if there was a less costly U.S. alternative to the "large footprint" flat plastic sheet machinery used in the Far East.

Axon's single- or dual-head systems--with rates of 60 and 120 bottles per minute, respectively--easily integrate into production lines and require very little conveyor space. Using a timing screw, they positively advance bottles in-line, ensuring each bottle receives one insert, or up to three as needed. They compact a length of FDA-approved 2-inch wide tubing into an accordion shape so the open ends, when inserted, spring into contact with the sides of the bottle.

Axon's technology is compatible with a wide choice of plastics at competitive prices. Preliminary indications, Axon says, are that film is one-third the cost of cotton. The films also are available in colors.

For more information

Axon Corporation--Styrotech 800-598-8601; www.axoncorp.com