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automation technologies

p ha r m a / co s m e t i cs

fo o d

da i ry

www.manesty.com

14:11 Uhr

accelacota
accelacota 150
accelacota 350
accelacota 750

established coating technology

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p ro d u c t s

p ro d u c t s

accelacota 150, 350, 750

With several thousand installations worldwide, the accelacota pioneered the way tablets could
be coated. Using sided vented pan technology, coating times were slashed and quality became
reproducible. Today using the latest in spray gun design, mixing baffles and control systems, the

short mixing times

reproducible quality

cost effective

effective drying

accelacota continues to take the science of coating to new heights.

established coating technology

02

12.05.2006

options

co nt ro l

proven
technology

t e c h n i c a l data

t e c h n o lo g y

m ac h i n e

p ro d u c t s

14:11 Uhr

manesty in house software design and support

12.05.2006

anti bearding gun

highly efficient spray technology

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03

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m ac h i n e

established coating technology

accelacota 150, 350 and 750
m ac h i n e

The accelacota is used as a model against which all other manufacturers units are compared.*
The accelacota range of coating equipment is the pharmaceutical industry's tablet coating
standard, benefiting from a proven global installed base of accelacota 150 and accelacota 350
and now joined by the new accelacota 750.

This high quality coating equipment,

The coater can also be provided with an

designed to cover a wide range of pro-

optional validatable clean in place system

duction batches from medium scale to

with strategically located cleaning nozzles,

large scale, has an unbeatable combina-

controlled by m-tec control system

tion of a very efficient coating process

technology.

coupled with a high rate of return on

investment.

effective drying
1

Innovative science based develop-

The fully perforated side-vented coater

ments in the four key areas of; tablet mix-

drum and cabinet design allows highly

ing, spraying, drying efficiency and con-

effective drying capacity in the process

trol system technology, guarantee that the

without the need to use high drying tem-

accelacota provides a very effective

peratures eliminating lower process effi-

solution to obtaining a highly controlled

ciencies (spray drying) and detrimental

process, ensuring the delivery of high

thermal stresses on the product.

temperature distribution in the

coating chamber

quality end product.

* Pharmaceutical Coating Technology,
Coley, Hogan and Aulton.

coating pan comparisons

manesty

competitors products

Perforated Pan

Partially Perforated Pan

Drying efficiency

High

Intermediate

Low

Turbulence

Low

High

Intermediate

Lower heat temperature

Higher inlet temperature

Highest inlet temperature

required due to high

required due to lower

as airflow is low

airflow

air flow

Processing conditions

Process efficiency

Extremely high

Low due to spray drying

(>98%)

caused by turbulence and

Solid Pan

Intermediate, around 90%

high inlet temperature

Process time

Short

Intermediate

Long

accelacota 150

accelacota 350

Suitable for medium scale production

Suitable for large scale production

Standard drum capacity 170 litres

Standard drum capacity 500 litres

Alternative drum capacity of 230 litres is available

Alternative drum capacities of 310 or 450 litres are available

Segmented drums available for pellet coating

Segmented drums available for pellet coating

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05

co nt ro l

t e c h n o lo g y

m ac h i n e

p ro d u c t s

internal cabinet view

options

key benefits
Low capital investment
Reduced cost of ownership
Unique mixing baffle designs

t e c h n i c a l data

Anti-bearding spray system

M-tec Integrated control system
Globally installed, proven technology
Minimal coating process times

accelacota drum capacities

number of

accelacota 750

spray guns

Suitable for large scale production

accelacota 750

Standard drum capacity 800 litres

accelacota 350

5 to 6

accelacota 150

3 to 4

Alternative drum capacity of 750 litres is available

800

750

700

650

600

550

500

450

400

350

300

250

200

150

100

size (litres)

nominal batch

50

Segmented drums available for pellet coating

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t e c h n o lo g y

established technology
why you should choose the manesty
accelacota with m-tec tm
t e c h n o lo g y

The accelacota range offers a high rate of return on investment.

m-tec fully modular control system. You determine the level of automation.

versatile
Offering the ability to cover a wide range
of batch sizes, process complexities and a
full range of optional equipment, meeting
all of your coating needs.

proven
1

A large global installed base of equip1

spray guns

ment, successfully coating tablets for

many years.

manesty
Our unrivalled process knowledge, equipment quality and after market support
ensures our customers are choosing the
number one supplier of coating equipment packages in the world.

accelacota 150
and accelacota 350

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t e c h n o lo g y

m ac h i n e

p ro d u c t s

07

t e c h n o lo g y

mixing efficiency

co nt ro l

tubular baffle

plougshare baffle

stealth baffle

manesty determine the product movement in the coating pan to be a key

options

attribute in the coating process. Effective mixing will give the benefits of low
product losses, low coating weight variability, eliminate product damage
and therefore increase productivity.

ploughshare

stealth

tubluar

Due to the unique designs of mixing baf-

mixing

fles offered on the accelacota range,

efficiency

High

controlled product movement and even

Applications

High friable products

Friable products

Products with

distribution of the coating solution is

Reduced batch sizes

Products with

friability <1%

achieved.

High weight gain

difficult flow

Sugar coating

characteristics

High

Highest

mixing times
Baffle designs have shown mixing times of
40 to 50 minutes. These times have been
determined using a Colourimeter to measure the colour build up on tablets during a
coating process.
colour
uniformity

key benefits
Baffle designs to cover all product forms
Increased productivity, reduced product variability
Reduction in material costs
Controlled product movement

55
50
45
40
35
30
25
20
15
10
5
0

1 mix
0

10

15

20

mixing time (mins)

25

30

35

40

45

Tubular

50

55

60

65

Ploughshare

t e c h n i c a l data

unique designs

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t e c h n o lo g y

new simulation technologies

opti coat tm spray science

t e c h n o lo g y

Computational Fluid Dynamics (cfd) simulation software has been utilised to gain an
understanding of the complex nature of the atomization process and has allowed engineers
to optimise the airflow characteristics of the microclimate, which occurs in the vicinity
of the spray gun nozzle and the form of internal liquid and air flow passageways.

air flow analyis

1

Mathematical model of spray gun and

manifold assembly.

Air velocity simulation over spray gun

and manifold.

In addition, manesty has considered how

as to generate a desired elliptical spray

the coater cabinet drying airflow is affect-

pattern. The Opti Coat spray gun air cap

ed in the region of the spray guns and its

design balances the need for anti-beard-

manifold assembly. This has led to a

ing characteristics with the requirement to

reduced spray gun profile design which

generate effective spray patterns.

also optimises the drying air passage to

the tablet bed surface, thereby achieving

droplet measurement

ideal conditions for coating film forma-

From a process perspective the overall

tion. By utilising new simulation technolo-

droplet size and distribution (span) will

gies manesty has adopted a science

influence the occurrence of process relat-

based design approach, which has led to

ed problems such as spray drying and over

the successful development of the Opti

wetting. The greater the control on

Coat spray gun. Many factors influence

droplet size the easier it will be to have a

the quality of the final film coated prod-

repeatable high efficiency coating process.

uct, some key study areas are:

By employing state of the art Laser

Diffraction Measurement technology,

spray pattern analysis

manesty has produced the Opti Coat

The difference in spray gun designs

spray gun to produce the narrowest

becomes more apparent when observing

droplet size distribution.

the spray patterns produced. At corre-

opti coat spray gun

The Opti CoatTM Spray Gun is the ultimate
choice for Pharmaceutical film coating.

Predictive capabilities manesty

sponding air pressures, a spray gun with

Process Scientists have developed a com-

large air outlet orifices produces an air

puter-generated matrix model providing

pattern that is less favourable in terms of

the ability to predict the influence of criti-

distribution of the solution onto the tablet

cal process parameters on droplet size and

bed. With competitor air cap designs spray

span, as well as process scale up.

pattern air pressures have to be higher so

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t e c h n o lo g y

manestys opti coat tm spray gun

By employing state of the art fluid flow simulation software and reviewing customer

p ro d u c t s

09

requirements, manesty has developed the Optimum Coating spray gun, the Opti Coat.
The Opti Coat spray gun includes considerable enhancements over existing spray gun
m ac h i n e

technologies and ensures manesty maintains its strong position as a world leader

cfd images
3

Air cap mesh

Air plume pressure contours

Droplet simulation

At the heart of the film coating process

Practice) and utilising materials accept-

the Opti Coat spray gun brings together

able for use by the Global Pharmaceutical

research from in-house Process Scientists

Regulatory Authorities for sealing and

and Design expertise to deliver a spray

construction, the Opti Coat spray gun

gun, which out performs the competition

is the ultimate choice for Pharmaceutical

in terms of performance and suitability for

tablet film coating.

options

co nt ro l

t e c h n o lo g y

in the film coating process.

customer requirements. Compliant in all

t e c h n i c a l data

aspects of GMP (Good Manufacturing

key benefits
Anti-bearding system with superior spray pattern
Enhanced droplet performance
Tool free, gmp compliant design
Low profile shape with integral connections
for reduced airflow turbulence
Retro-fit capability to upgrade existing coating equipment
Recirculation option

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co nt ro l

co nt ro l

m-tec control system technology

manesty coater systems are equipped with the latest m-tec control system technology. This provides
complete control of the coating process including air handling and solution delivery, as well as subsequent clean in place requirements. The control system is common across the entire range of coating
machines available from manesty, including the laboratory xl lab, the premier and of course the
accelacota. m-tec systems are tailored, specific to customers requirements by building from a library
of generic modules. These packages can be upgraded later as user needs change or develop.

architecture and design

steel keyboard (shown). Hazardous area

automation manager

m-tec control system design takes

option also available.

Powerful configuration tools provided for

advantage of years of coating experience

flexible automation. Automated

users to develop recipe driven automation

and through in-house software develop-

sequences tailored to suit customers

for both coating and cip operations.

ment, provides the most intuitive operator

process requirements.

Consistent with industry batch standards.

interface. Primary design focus on process

data exchange. Integration to com-

recipe management. Product recipes

functionality provides great alignment

pany networks and batch management

can be created from pre-built recipe

with user requirements.

systems available using industry stan-

method templates prior to release to pro-

dards.

duction.

robust machine control. plc based

m-tec . Utilises Microsoft Technology

recipe method editor. For develop-

Machine Control to handle control devices

and opc communications. User Access

ment of custom recipe method templates.

and safety systems.

Control management. Designed to enable

operator hmi. pc based Operator

regulatory compliance with cgmp, gamp

reporting tools

Interface withTouch Screen and stainless

and fda 21 cfr part 11.

Range of Reporting and Trending packages to support manual operation and

flexible automation. Accurate data acquisition and comprehensive production
records, suitable for use in 21 cfr part 11
compliant systems. Ensures High Level of
Traceability.

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m ac h i n e

p ro d u c t s

11

co nt ro l

t e c h n o lo g y

advanced process control

Manual Cleaning Functions

Closed loop control of

Maintenance level access allows direct

all process critical parameters

drive of equipment and control devices

Process Alarming

3 automated operation

Secure Machine and

Recipe driven automation

Process Interlock handling

of the coating process

Ensures high level of repeatability

Recipe driven automation

options

Ancillary Equipment Control

of the integrated clean in place system

Process Endpoint Determination

Manual production control and batch

Flexible recipe methods, tailored

record generation.

to customer requirements

Easy and consistent operation using

automated coater and ancillary equipment start up sequences

key benefits
Common, scaleable, platform for r&d, Pilot Plant and Production
Standard Operation, Reporting and Automation
Improved Maintenance and Process support
Modular software to enable easy upgrade path
Enables regulatory compliance
In house software design ensures continuous support

t e c h n i c a l data

2 manual operation

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12 o p t i o n s

flexible coating
capability from manesty
opti0ns

As you would expect from a worldwide supplier of coating systems, a range of optional equipment
and services are available to suit budget, process, regulatory and climatic requirements. As a
major innovator in side vented pan technology for over 30 years, use our proven design and
process support personnel to optimise the design and implementation of your coating requirements.

key

design expertise

ply and installation, positioning of equip-

Take advantage of our knowledge to

ment, utility connections, commissioning,

ensure ductwork specifications and rout-

validation and training take advantage of

ings meet process requirements at the

manesty s One Stop Solution.

coater and exhaust air is safely taken away.

We can save you time by calculating all

inlet air handling

the important hvac requirements to allow

As we supply our accelacota Coaters

the coating process to be the most effi-

worldwide, different climatic conditions

cient possible.

require a custom made solution for the

delivery of process air at the correct vol-

turnkey installation

ume, temperature and humidity. Our

Increasingly, customers are looking for a

modular and flexible air-handling units

complete solution not only for their

condition the incoming air to meet the

equipment needs but also for its safe and

required process conditions. Options

rapid installation and its associated servic-

include preheating, humidity control, and

es and utilities. This ensures that a single

filtration. The units can also be flexibly

main contractor takes responsibility for

installed as single horizontal line or in a

the complete line, guaranteeing smooth

dual deck format to optimise the use of

transition to full operational status. From

available space.

design, health and safety, ductwork sup-

Exhaust Filter Unit

Exhaust Air Duct

Inlet Air Duct

Air Handling Unit

Supervisor Station

Operator Interface

Coater

Spray System

Solution Vessel

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13

m ac h i n e

p ro d u c t s

7
6

t e c h n o lo g y

solution delivery systems

post delivery support

Once again a range of options are avail-

The new Opti Coat spray gun is sup-

Following delivery to your site our com-

able to remove the air from the accela-

ported by an efficient peristaltic pump

missioning personnel will ensure per-

cota Coater. From a simple Mechanical

delivery system. This ensures excellent

formance to SAT requirements. Fully

Shake System to Full Safe Change capa-

control of solution delivery as the pump

comprehensive validation documentation

bility to handle potent compounds, we

speed is controlled by the m-tec control

will ensure that your new accelacota

can provide the appropriate solution for

system. By simply switching tubing a

Coating System fully supports the appro-

you. To ensure there is no water damage

range of aqueous and organic solvents can

priate regulatory requirements that you

to the filters during the Clean in Place

be successfully used. Individual monitoring

need to comply with. The IQ and OQ ele-

process a bypass system is fitted as stan-

of the performance of each solution line is

ments of this documentation can also be

dard.

also available. Other delivery systems are

implemented by manesty personnel (in

available to enable the coating of tablets

support of your own staff) to allow the

clean in place (cip)

with sugar suspensions or more difficult

start of PQ testing in the shortest possible

In conjunction with our m-tec control

organic solvents if required.

time.

system we can provide a fully validatable

clean in place option to remove all con-

loading and unloading solutions

taminates. This avoids the need to under-

Typically, tablets are delivered into the

take further manual work which is often

drum via a loading chute or a material

the case at the end of a wash in place sys-

handling system via the door of the coater.

tem. From the initial rinse through to

100% of tablets will be discharged

compressed air cleaning of solution tubes,

through the front of the coater by using

The accelacota incorporates a proven

our reverse unloading package. This valu-

CIP design. Our package will ensure you

able option quickly and safely removes

will be coating your next batch of tablets

tablets from the drum and delivers them

in the minimum possible time.

into your container.

t e c h n i c a l data

exhaust air handling

options

co nt ro l

Control functionality depends on optional package purchased.

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Seite 15

14 t e c h n i c a l data

t e c h n i c a l data

specifications

accelacota 150

2196

1200

1962
2327

2062

1665

1309
1474

accelacota 350

1275

2581

2621

2295

2398

2050

1631
1795

t e c h n o lo g y

3100

2414
2595

co nt ro l

2050

options

m ac h i n e

accelacota 750

t e c h n i c a l data

2700

p ro d u c t s

14:12 Uhr

2295

12.05.2006

2398

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15

1900

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Seite 1

Worldwide addresses and contacts.

aerofill
33-35 Clayton Road
Hayes . Middlesex ub3 1ru
Great Britain
p +44 2088 4845 01
f +44 2085 6133 08
sales@aerofill.com
www.kpaerofill.com
benz & hilgers gmbh
Blindeisenweg 17
41468 Neuss . Germany
p +49 2131 9955 33
f +49 2131 9300 55
sales@benhil.de
www.benhil.de

europe

america

iwk verpackungstechnik gmbh

Lorenzstrae 6
76297 Stutensee . Germany
p +49 7244 968 0
f +49 7244 960 73
vpt@iwka.de
www.iwk-vpt.de

erca-formseal ibrica s.a.

C/Gerona . 12 . Nave D
p.i. La Post . 08850 Gava . Spain
p +34 93 662 3800
f +34 93 662 5458
ercasa@diagram.es
www.ercaformseal.com

hassia usa inc.

1210 Campus Drive West
Morganville . nj 07751 . usa
p +1 732 5368 770
f +1 732 5368 850
sales@hassiausa.com
www.hassiausa.com

manesty
Kitling Road . Knowsley
Merseyside . l34 9js . Great Britain
p +44 151 547 8000
f +44 151 547 8001
sales@manesty.com
www.manesty.com

iwk machines demballage s.a.s.

Avenue Augustin Normand
b.p. 30 106
14603 Honfleur Cedex . France
p +33 231 816 590
f +33 231 816 081
standard@iwk.fr

iwka pacsystems inc.

39 . Plymouth Street
p.o. Box 716
Fairfield . nj 07006 . usa
p +1 973 227 5575
f +1 973 227 4820
sales@iwkapacsystems.com
www.iwkapacsystems.com

packaging systems gmbh

Werkstrae 2
32278 Kirchlengern . Germany
p +49 5223 97697 0
f +49 5223 97697 11
info@packagingsystems.de
www.packagingsystems.de

iwka pacsystems ltd.

4 Hurland Business Centre
Hurlands Close
Farnham . Surrey . gu9 9je
Great Britain
p +44 870 011 37 94
f +44 870 011 37 95
info@iwkapacsystems.co.uk
www.iwkapacsystems.co.uk

america

dawson
Stephenson Way
Thetford . Norfolk ip24 3ru
Great Britain
p +44 1842 7535 05
f +44 1842 7535 08
info@dawson-uk.com
www.dawson-uk.com

fabrima mquinas
automticas ltda.
Av. Narain Singh . 577
Parque Industrial de Bonsucesso
cep 07250-000
Guarulhos-SP . Brazil
p +55 11 6465 2500
f +55 11 6480 3934
vendas@fabrima.com.br
www.fabrima.com.br

erca-formseal s.a.
3 . Avenue du Pacifique
Les Ulis . b.p. 54
91942 Courtaboeuf Cedex
France
p +33 169 828 000
f +33 169 078 238
ulis@erca-formseal.com
www.erca-formseal.com

packaging technologies inc.

807 West Kimberly Road
Davenport . ia 52806 . usa
p +1 563 391 1100
f +1 563 391 0017
sales@packt.com
www.packt.com

gasti
verpackungsmaschinen gmbh
Raiffeisenstrae 8
74523 Schwbisch Hall
Germany
p +49 791 402 0
f +49 791 402 100
info@gasti.de
www.gasti.de
hassia-redatron gmbh
Schorbachstrae 11
35510 Butzbach . Germany
p +49 6033 7474 0
f +49 6033 7474 185
redatron@iwka.de
www.hassia-redatron.de

r.a. jones europak

Unit 30 . Concourse House
432 Dewsbury Road
Leeds ls11 7df
Great Britain
p +44 113 276 5842
f +44 113 270 9783
inquiry@rajones.com
www.rajones.com
ooo iwka packaging
Denisowskij Pereulok
Gebude 26
105005 Moscow . Russia
p +7 495 933 32 13
f +7 495 933 32 19
dmitriev@iwka-packaging.ru

r.a. jones & co. inc.

2701 Crescent Springs Road
Covington . ky 41017 . usa
p +1 859 34 104 00
f +1 859 34 105 19
sales@rajones.com
www.rajones.com
tecmar s.a.
G. Matteoti 64 esq. Sols
7600 Mar del Plata
Prov. De Buenos Aires . Argentina
p +54 2234 8100 08
f +54 2234 8270 15
ventas@tecmarsa.com
www.tecmarsa.com

asia

hassia
verpackungsmaschinen gmbh
Heegweg 19
63691 Ranstadt . Germany
p +49 6041 81 0
f +49 6041 81 213
info@hassia.de
www.hassia.de

hassia-redatron
packaging machinery pvt. ltd.
768/3 Sanaswadi
Taluka Shirur
District Pune 412207 . India
p +91 2137 2532 10
f +91 2137 2532 06
redatron_india@vsnl.com
www.hassiaredatron.com

httlin gmbh
Daimlerstrae 7
79585 Steinen . Germany
p +49 7627 9117 0
f +49 7627 8851
info@huettlin.de
www.huettlin.de

iwk packaging machinery ltd.

49/45 Moo 9 . Srinakarin Road
Kwaeng Bangna . Khet Bangna
Bangkok 10260 . Thailand
p +66 2 39937523
f +66 2 3993755
matthias.juengling@iwkathai.com

manesty | Kitling Road . Knowsley . Merseyside . England . United Kingdom . L34 9JS
t +44 151 547 8000 . f +44 151 547 8001 . www.manesty.com

MONTFORT

a + f automation und
frdertechnik gmbh
Industriestrae 11-13
32278 Kirchlengern . Germany
p +49 5223 8791 0
f +49 5223 8791 11
info@afautomation.de
www.afautomation.de

pack & process s.a. de c.v.

Avenida Insurgentes Sur 605
Oficina 1005 . Col.Npoles
03810 . Mxico . d.f. Mexico
p +52 55 360 490
f +52 55 360 490
info@pack-process.com
www.pack-process.com

asia
iwka packaging shanghai
representative office
Feizhou Cross Region Plaza
27th Floor . Unit b
899 Lingling Road . Xuhui District
Shanghai 200030 . p.r. China
p +86 21 5150 6306
f +86 21 5150 6309
libauer@iwkapu-sha.com

Technical data and illustrations, non-binding for delivery. Subject to change.

europe

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Distribution companies

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