Packaging Technology

Track & Trace and Serialization Solutions

2 | CPS – Track & Trace

A Serialization Solution with CPSOur machine portfolio includes printing, verification, weighing and labeling solutions, as well as a Tamper Evident function (application of security labels). The modules are able to communicate with host systems. Thanks to object-oriented programming and a results-based approach, the expansion of their use to include serialization and aggregation applications with all CPS solutions is implemented. A tool-free format change capability and a mainte- nance-free conveyor belt system ensure optimum line integration. If necessary, the global Bosch service network guarantees the rapid availability of spare parts and expert on-site assistance.

With the modular printing and verification systems from Bosch Packaging Technology, you will be optimally equipped to meet current and future market demands with respect to counterfeit protection and product tracking

For many years, Bosch has been successfully applying tracking and tracing systems with respect to safety-related parts and components. The expertise gained in the automotive industry is now set to benefit the pharmaceutical sector in the form of a cutting-edge, object-oriented and results-based tracking solution.

The strictly modular Bosch Track & Trace machine concept allows printing, verification and IT systems to be effortlessly integrated into existing production and packaging lines. Our software specialists develop regulation- compliant IT solutions for our clients for handling serialized and job-related data.

By procuring the CPS machine concept, you invest in a fully customized, future-proof solution for serializing and tracking blister packages, bottles, cartons, bundles, shipping boxes and pallets.

CPS – Flexible serialization solutions for the pharmaceutical industry

As a flexible, stand-alone solution, the CPS carton printing and verification system is designed for easy integration into both existing and new production lines. Its precise mechanical construction ensures maximum production efficiency and contributes to a production line’s optimum overall performance. The employed printing and verification systems fulfill all standards and international regulations for carton labeling and serialization within the pharmaceutical industry.

An open system in terms of its modular and scalable design, CPS may not only be equipped with the widest variety of marking systems and monitoring cameras, it also offers an excellent range of functional expansion possibilities (e.g. verification checkweigher, labeler, Tamper Evident function). It can be expanded to a perfectly customized overall system with a centralized HMI control panel.

The HMI control panel coordinates the machine and the printing and verification equipment, as well as possible functional extensions into an easy-to-operate overall concept. All production, printing and layout data are centrally managed and configured.

Furthermore, CPS is equipped with an integrated line management system, which handles the system’s communication with IT host systems, e.g. MES or ERP. Serial numbers and batch data

are received by the CPS system and managed by the line process. In addition to product serial-ization, the line process is also able to control and manage the process of product aggregation. Its software architecture allows the expansion for all necessary levels of aggregation (e.g. bundles, shipping carton, pallet).

The CPS series at a glanceUsing the least possible amount of installation space, the CPS 0800 base module prints and verifies up to 400 cartons per minute. Its separately adjustable conveyor belts allow cartons to be secured for printing on their side flaps from the front and/or the rear, as well as on the cartons’ top and/or bottom sides. The CPS 0800 can be equipped with the widest variety of marking systems (e.g. inkjet, laser, etc.) from all common brand-suppliers, and can thereby be individually adapted to any client’s applications.

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All modules in the CPS series can be expanded according to requirements and functionality. The modular concept of the CPS series combines the processes of printing or marking, verifying, weig-hing and labeling with standard and security labels in one single machine and in a very small space.

cGMP-compliant, space-saving and easily accessibleCPS machines are designed strictly according to cGMP guidelines. Their balcony design is open at the bottom and is easily accessible and easy to clean. Excellent accessibility to every module is assured thanks to rear-mounted control-switch cabinets and pivoting operating consoles. The very short length of CPS modules allows them to be integrated into any existing or new packaging line. All format data is individually stored, enabling quick and easy format changeovers that can be accomplished reproducibly, simply, and quickly, assuring a safe and reliable restarting of the machine.

Rapid and reproducible format changeoversAll CPS modules come equipped with a tool-free quick-change system. According to requirements, the printer and camera may be easily repositioned either toward the front or the rear, or in order to perform printing and verification from above.

▶ Carton print and verify system for product serialization

▶ Flexible stand alone solution▶ Precise mechanical design

for highest encoding quality and line efficiency

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In addition to the CPS 0800 base module, a wide range of modifications to meet various requirements are available.

With the CPS 0800, cartons may be both printed and verified. All CPS series are equipped for product serialization tasks.

With the CPS 1400 with checkweigher, cartons can be printed, verified and weighed.

With the CPS 1600 with labeler, cartons can be printed, verified and labeled.

With the CPS 1900 with checkweigher and labeler, cartons can be printed, verified, weighed and labeled.

With the CPS 1900 with checkweigher and Tamper Evident function, cartons can be printed, verified, weighed, and have security labels applied. It can be equipped with up to two security label dispensers. This modular expansion is also optionally available without a checkweigher.

With the CPS 0400, the semi automatic aggregation solution, cartons can be easily and safely packed and aggregated into a case.

Products and ApplicationsPrinting and monitoring positionsBy using the tool-free quick-change system, the printer and camera may be repositioned with only a few manual adjustments either toward the rear or upward. This system also facilitates attaching multiple print heads for simultaneous printing (e.g. of the back and front). This offers the possibility to print different data as a 2D code on one flap and the variable readable data on the opposite flap, for example.

LabelerThe CPS module can easily be supplemented with a labeler, in case the application of country-specific labels is required in addition to inline printing (e.g. Bollini, price labels, etc.).

Tamper Evident functionCPS offers a solution for securing cartons against tampering, whereby both side flaps may be sealed either underneath or on top of the carton, as required. Thanks to the overall modular design, the Tamper Evident feature is optionally available for all CPS machines as wellas existing CPS 0800 modules. The presence of the tamper evident label will be checked.

Printing and marking technologiesIn order to comply with varying international and future requirements regarding serialization and product tracking, all commonly used marking systems may be integrated and mounted. For instance, serial numbers, 1D and 2D codes, batch data and expiry dates can be applied with ink or laser. Such data may be applied in plain text and encoded as machine-readable codes. Likewise, the marking of RFID labels is possible.

Monitoring and verification technologiesThe monitoring and verification of data applied during the packaging process is carried out in real time. OCR/OCV camera systems are used to read and verify all commonly employed types of codes and type sets, e.g. data matrix code and plain text. Meanwhile, the in-line grading feature constantly monitors printing quality. The quality-related data are then made available in the form of exported files, which may be routed to host systems. The reading of RFID labels is also possible.

Carton printing and verification at maximum flexibility

1D and 2D code serialization as well as Tamper Evident Solution

Central access for Track & Trace application

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Serialization > Aggregation > InterfaceSerialization and aggregation present the IT departments with particularly demanding challenges. Not only must the packaging processes be synchronized with the newly integrated procedures. At the same time, entirely new processes have to be developed for the consistent and safe management and storage of serial numbers. The integration of packaging machines into these new procedures is an essential component of each serialization project. It requires careful planning to unambiguously and permanently store the serial numbers at the required integration level – from application level, line process and line management through to production and enterprise level.

SerializationA serial number is assigned to each package and is recorded in a database, where it can be verified at any time. This can be done with a host system or the serial numbers can be generated locally. Both versions require reliable process execution and feedback of the serial number circles. Furthermore, new processes for managing and saving the serial numbers are implemented.

Therefore a multi-level machine and software concept is employed. After printing the tracking data on the carton, automatic verification takes place via the camera system.

AggregationTo control both operating condition and data at any time, the connection between the physical machine level and the control software must be integrated across many stages of the company’s IT. The Track & Trace system evaluates data in real time and answers the following questions: Where exactly is which product located? Which information is available about this product? This includes information on the code content, the current overall aggregation and production status, as well as quality data such as possible error patterns and weight indications. All results are reported to superordinate ERP systems on the enterprise level. An expansion to all necessary aggregation levels as bundles, delivery cases or pallets can also be achieved with this software architecture. This ensures that existing and future market requirements are met. Customized line solutions can be realized with a minimum integration effort.

Serilisation and Tamper Evident – with highest process reliability

Modular standard interface to ERP and MES applications Data transfer of:▶ Batch and production information▶ Serial numbers▶ Machine and production

line status▶ Detailed product information:

e.g. weight, 2D matrix grading, product status

8 | CPS – Track & Trace

Packaging Line Solution Our CPS units have been designed using a modular and space-saving approach. Their software is based on object-oriented programming and a result-based approach.

A modular machine and software concept was developed in order to meet the widest variety of market requirements. This concept makes it possible to realize customer-specific production line solutions, such as packaging lines for both solid and liquid products, without a high degree of integration-related complexity or compromise to overall line performance.

The employment of object-oriented programming and a result-based approach offers generic software modules that allow the implementation of any market-specific or client-specific require-ments. Other functionalities, such as future types of coding, may be added without having any impact on the existing, validated modules’ performance.

Product Level▶ Inspection▶ Print & Verify

Primary Packaging

Marking

Verification

Reject

HMI

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Item Level▶ Print & Verify▶ Serialization

Aggregation Level ▶ Product Aggregation▶ Exception-Handling▶ Re-Work

Secondary Packaging

HMI HMI

Hand scanner Hand scanner

Marking

Verification

Reject

Marking Marking

Verification Verification

10 | CPS – Track & Trace

Software Structure

At machine level, Track & Trace implies keeping track of products and their associated data. Information must be evaluated in real time, and an assertion must be derived from this infor- mation: Where exactly is which product located, and which information is available about this product?

The results of all observations and actions must then be reported to the host systems.

The Track & Trace process in packaging lines is as unique as only processes of various machine types in other production lines can be. In order to map the entire Track & Trace process so that its software functionalities are applicable in different projects, the Track & Trace solution from Bosch is founded on an object-oriented, result-based software platform.

The generic approach makes it possible to design a non-redundant configuration for each packaging line. This eliminates the need to modify the software for each Track & Trace process. With the Track & Trace solution from Bosch, new software development is thus only necessary for the addition of new functionalities. It is added to the overall software program without impacting existing software capabilities.

Track & Trace processes usually require having to communicate intensively with other IT systems (e.g. MES, ERP). Our Track & Trace solution supports EPCIS (Electronic Product Code Information System) as a standard interface. EPCIS is an international standard interface used to communicate any product- related events and to retrieve product-related data.

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Track & Trace Software Architecture

Devices

Line Process

Line Process

(2.2) Line Connection

MES

T&T (IT Solution)

(2.1) Local Management

(1.1) Station Process 1 Station Process n

Line Management

Production Control

Enterprise Control4 ERP

P&VHMIHMI

HMI

3

2

1

0

InspectionUnit

P&V and Aggregation

T&T =Track & TraceP&V = Print and Verify

IN

Buffer

OUT IN OUT

Buffer Buffer Buffer

VisionPrinter Vision Eject Vision Printer

12 | CPS – Track & Trace

Technical Data

Front view

Right reserved to effect technical modifications

CPS 0800 CPS 1600CPS 1400

* + 100 mm

Configuration Print & Verify Print & Verify Print and Verify Print & Verify Print & Verify Semi automatic aggregation with checkweigher with labeler with checkweigher with Tamper Evident function solution with hand scanner and labeler Option: with checkweigher and labeling station

Carton dimensions (A x B x H in mm) min. 15 x 10 x 40 min. 25 x 10 x 40 min. 25 x 20 x 60 min. 25 x 10 x 60 min. 25 x 20 x 80 min. 15 x 10 x 40

max. 125 x 125 x 260 max. 125 x 125 x 200 max. 125 x 125 x 260 max. 125 x 125 x 260 max. 125 x 125 x 200 max. 125 x 125 x 260

Size (A x B x H in mm) 834 x 1,240 x 2,053* 1,486 x 1,240 x 2,053* 1,637 x 2,443 x 1,193* 2,034 x 1,240 x 2,053* 2,034 x 1,240 x 2,053* ca. 1,900 x 1,000

Running height (in mm) 800* 800* 800* 800* 800* 800*

Max. output (in ppm) 400 at max. 60 m/min 350 at max. 60 m/min 350 at max. 60 m/min 350 at max. 60 m/min 300 at max. 60 m/min 60

Energy supply (in KW) 1 1 1 1 1 2.5

Load requirements (in V) 230/400 230/400 230/400 230/400 230/400 230/400 special voltage possible special voltage possible special voltage possible special voltage possible special voltage possible special voltage possible

Compressed air requirement (in Nl/min) 30 60 30 60 60 30

CPS 1600CPS 1400CPS 0800

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CPS 1900 CPS 0400CPS 1900 Configuration Print & Verify Print & Verify Print and Verify Print & Verify Print & Verify Semi automatic aggregation with checkweigher with labeler with checkweigher with Tamper Evident function solution with hand scanner and labeler Option: with checkweigher and labeling station

Carton dimensions (A x B x H in mm) min. 15 x 10 x 40 min. 25 x 10 x 40 min. 25 x 20 x 60 min. 25 x 10 x 60 min. 25 x 20 x 80 min. 15 x 10 x 40

max. 125 x 125 x 260 max. 125 x 125 x 200 max. 125 x 125 x 260 max. 125 x 125 x 260 max. 125 x 125 x 200 max. 125 x 125 x 260

Size (A x B x H in mm) 834 x 1,240 x 2,053* 1,486 x 1,240 x 2,053* 1,637 x 2,443 x 1,193* 2,034 x 1,240 x 2,053* 2,034 x 1,240 x 2,053* ca. 1,900 x 1,000

Running height (in mm) 800* 800* 800* 800* 800* 800*

Max. output (in ppm) 400 at max. 60 m/min 350 at max. 60 m/min 350 at max. 60 m/min 350 at max. 60 m/min 300 at max. 60 m/min 60

Energy supply (in KW) 1 1 1 1 1 2.5

Load requirements (in V) 230/400 230/400 230/400 230/400 230/400 230/400 special voltage possible special voltage possible special voltage possible special voltage possible special voltage possible special voltage possible

Compressed air requirement (in Nl/min) 30 60 30 60 60 30

CPS 0400CPS 1900

Robert Bosch GmbH Packaging Technology Product Division Pharma Solid

Stuttgarter Straße 130 71332 Waiblingen Germany Phone +49 711 811-0 www.boschpackaging.com packaging-ph@bosch.com

For more information, please visit:

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