Sustainable innovation via tailored retrofit of combined unit
This project proved that innovation does not always require starting from scratch. With the right engineering expertise, it is entirely possible to extend the lifetime of functioning machinery while elevating safety and quality standards to the highest possible level in compliance with the current regulations.
The challenge
In solid dosage manufacturing (tablets and capsules), line efficiency relies on the seamless synergy between product dedusting and quality control by the metal detector. Often, production managers face a tough dilemma: they own a combined system (Deduster/Capsule Polisher + Metal Detector) where the metal detector is obsolete, lacks compliance with modern regulations (such as FDA 21 CFR Part 11), or lacks sensitivity, yet the mechanical dedusting unit is still robust, reliable, and functional.
THE CUSTOMER'S DILEMMA: Invest in a brand-new combined system, or risk non-compliance by running an outdated, end-of-life metal detector?
This was the precise challenge faced by one of the largest pharmaceutical companies in Slovenia. The decision, along with the under-consideration CAPEX, involved a total of thirteen (13) combi units.
The solution: strategic & selective retrofit
The smartest and most sustainable answer was a selective retrofit. Our dedicated engineering team designed a seamless mechanical and electronic integration, allowing the customer to upgrade their quality control standards by installing the state-of-the-art CEIA THS/PH21N Metal Detector, while fully preserving their existing, robust tablet deduster.
This custom-engineered upgrade was achieved with zero modifications to the original line footprint and no reduction in mechanical throughput, eliminating the need for costly factory floor reconfigurations.
To ensure business continuity for one of Slovenia’s largest pharmaceutical plants, the validation and installation process was executed in a phased approach: the thirteen combi units were divided into four separate groups. This minimized downtime, allowing the plant to maintain a high and steady production rate throughout the entire transition.
Maximum flexibility with certified expertise
Furthermore, this selective retrofit offers exceptional logistical flexibility. If shipping the machinery to our facili¬ties is not feasible, or if minimizing production downtime is an absolute priority, the upgrade can be performed directly on-site at the customer’s plant. To guarantee seamless integration, maximum safety, and full regula¬tory compliance, the intervention is executed directly by authorized CEIA service personnel. This on-site expert service ensures the line is upgraded rapidly and validated according to the highest industry standards, keeping production downtime to a bare minimum.
Technical & economic benefits
Applying a targeted retrofit delivered immediate advantages across two critical areas:
- STATE-OF-THE-ART TECHNOLOGY: The customer gained significantly higher detection sensitivity (Fe 0.25 mm, Non-Fe 0.30 mm, Stainless Steel 0.40 mm), advanced fail-safe reject monitoring, full compliance with current regulatory standards, and an intuitive HMI for rapid product changeovers;
- MAJOR COST SAVINGS (CAPEX OPTIMIZATION): By avoiding the purchase of a new deduster/polisher and eliminating the need for major structural modifications to the line, the customer saved an estimated 50% compared to buying a completely new combined system;
- SUSTAINABILITY & REDUCED DOWNTIME: This approach aligns with circular economy principles by reducing industrial waste and drastically shortens installation and validation times compared to deploying an entirely new machine.
Conclusion
This project proved that innovation does not always require starting from scratch. With the right engineering expertise, it is entirely possible to extend the lifetime of functioning machinery while elevating safety and quality standards to the highest possible level in compliance with the current regulations.