Aylward-Elmach:Innovations in Counting & Filling Technology
Mr. Frank Brown dedicated approximately 30 years of his career (1978-2007) to what eventually became Procter & Gamble Pharmaceuticals in the early 1980s. He was assigned as a project engineer to technology leader. He was responsible for the pharmaceutical packaging equipment processes for packaged products in countries like the USA (including Puerto Rico), Germany, France, Italy, and Austria. He developed equipment specifications that led the procurement, testing, installation, and qualification of the equipment from purchase to packaging of products. In 2007, he joined Aylward Enterprises in North Carolina as a product manager and was responsible for blister pack feed systems. After their acquisition by Elmach, he has been appointed as President and CEO of Aylward Enterprises, a part of Elmach Group.
Aylward-Elmach: Innovator in Tablet Counter
Intro
Founded in 1977, Aylward has become the world’s leading supplier of specialized, solid dose packaging equipment. The original inventor of dedicated blister feed systems, the company continues to innovate and currently designs and manufactures 100% accurate counts for Tablet Counters, Blister Machines, Cartoners, and Custom Packaging Automation.
It’s fascinating to hear about the evolution of Aylward Enterprises from feeding systems to packaging solutions. Mr. Frank Brown, the President and CEO of Aylward Enterprises, shared the company’s journey with Pharma Machines & Technology during Pmec India 2023.
“He was known as a “Tinkerer” by locals. It seems like he had a knack for coming up with innovative solutions to the problems faced by local manufacturers. He was John Aylward, sole founder of Aylward Enterprises.” The innovation begins in the early 1970s. A local manufacturer approached the founder, Mr. John Aylward, to develop an innovative feeder for their candy wrapping process. John Aylward’s innovative idea for a better feeding system for candy wrapping came to life in his garage in New Jersey. Through research and after a series of trials, he developed the dedicated tube feeding system, which replaced the inefficient “flood feeding” method to supply candy drops to the vertical wrapping machines. The tube feeding system reduced waste wrappers. As the invention gained popularity in feeding systems and for further expansions, the company moved to North Carolina in 1980 and where it still operates today. The dedicated tube filling feed system was introduced to the pharmaceutical world, which reduced waste, and its success led the company to become the dedicated supplier of tube filling feed systems worldwide. Various portions of the feed systems are still patented today. It is also impressive to learn that despite many copies by different OEMs in the market, none of them can claim to be able to feed every style of solid dose product. Aylward’s customers include the world’s leading pharmaceutical, consumer health, animal health, and contract packaging companies. Today, the company has expanded its sales and service facility in Riedlingen, Germany, and its headquarters remain in New Bern, North Carolina, USA.
Q. What are the technological advantages and key values that make Aylward the leader in tablet and blister feeding?
A. We can guarantee that only a single product is dispensed into the blister cavity at a time through the design of the Aylward blister feeding dedicated tube system. This is accomplished via a series of pins and pin plates that physically separate the product from each other, thus allowing only a single product to drop without any damage being done to the product. The feed system and tubes are designed using the customers’ web layout and product specifications. This design enables us to guarantee a feeding efficiency of 99.8%. We will demonstrate this to the customer during an on-site FAT (Factory Acceptance Test) at our facility in North Carolina using the customers preformed web and customer provided product. This leads to a seamless installation and start up for the customer at their facility.
Q. Being the inventor of blister feed systems, Aylward is now going to define the new era of bottle filling. What can we expect?
A. Aylward has introduced high speed bottle filling with speeds up to 350 bottles per minute and committed to a 100% count accuracy. This is accomplished through a series of sensor banks placed just before the bottle fill area. The specific design of filling drums allows for single product movement throughout the filling process and allows the counting of every tablet individually. We bring the same rigor to this process, similar to the process of blister feeding systems. Our newest innovation is the TCM, launched at the PMEC India 2023 exhibition in Greater Noida, Delhi NCR. The equipment is designed to inspect and count the products that are currently unavailable in the market. The system inspects the product conditions and rogue colors and counts for the preset amount. In case of rejection, the product is taken out of the stream before it enters the bottle. A method referred to as “rejected on the fly.” This gives 100% accuracy to fill the container.
Q. How would your bottle filling line be different from other systems in the industry?
A. The Aylward TCM is a revolutionary design that allows for the product to be inspected and counted at the same time before it enters the container. Both of these functions are built into the machine up front, so there is no need for additional equipment to perform the tasks. The product is held in place by a vacuum on the fly and rests in a specially but versatile designed cavity of the product disc. This allows to inspect and count products on the fly. The verified product is filled in the bottle, and the rejected product is dispensed into the staged container. The TCM efficiently identifies and rejects defective products before dispensing them into the product container, preventing the creation of reject bottles and enhancing overall productivity. Additionally, its design is conducive to accommodating environmental containment, making it suitable for handling potent substances like anti-cancer medications
Q. What are the opportunities you see in the bottle filing systems in India as well as globally?
A. We believe that the Aylward TCM will be a game changer in the bottle filling arena for India. No other machine accomplishes inspecting and counting in the same footprint. As more and more companies move towards bottle filling, we believe our equipment will fill the void successfully. The TCM is designed for mid-range output speeds up to 60-70 bpm. Aylward also supplies high-speed bottle fillers for output ranges up to 350 bpm. Our high speed bottle fillers use a different method to transport the product from bulk hopper to bottle, although still applying vacuum to hold the solid dose in a cavity milled into a drum versus on the outside of a disc. These machines are installed and are running successfully at numerous pharmaceutical companies globally for packaging solid dose products.
Q. How would the Indian pharma industry benefit from the Aylward-Elmach combination? What does the association with Elmach mean to Aylward?
What does the association with Elmach mean to Aylward?
A. As a result of the Elmach acquisition of Aylward, we are now a full-service blister packing line manufacturer in India. Elmach has become one of the top blister machines & cartoning line manufacturer in their region. Blister machines always require solid dose feeding systems. Whether track feeders, flood feeders, or dedicated tube feeding systems. The feeding system is the heart of the process. After acquisition, both companies will now represent customers in India and worldwide with complete world-class blister packing systems. Aylward will now have access to Elmach’s network of sales resources. At the same time, Elmach will have access to markets that Aylward currently supports throughout the world. Aylward will benefit from cost effective machines manufactured by Elmach without compromising quality. Elmach will be able to take advantage of the technology transfer that Aylward brings to the table. Aylward-Elmach team will benefit the customers in India and worldwide.
Q. What are the machinery and technology solutions would the Aylward-Elmach team offer to the pharma industry worldwide? What are the growth expectations globally as well as in India?
A. Our newly formed partnership will provide pharma manufacturers worldwide with state-of-the-art blister packing and bottle-filling machines. The Aylward bottle-filling technology offers customers a means of guaranteeing 100% count accuracy versus conventional bottle-filling technology. The newest innovation (TCM) offers the ability to provide product inspection for color, condition, or rogue products while verifying count accuracy. With Elmach’s global presence, quality machines, and craftsmanship, the company’s value will expand to the Western hemisphere markets and add value to its existing prominence, which is achieved through more than 4,800 machines running worldwide.
Q. Being part of Procter and Gamble for so many years would mean a vast experience in the field of bottle filling lines. Would you be open to sharing this experience and knowledge with Indian companies who are moving towards setting up new bottle filling lines or upgrading their existing lines.
A. I would be glad to assists and if anybody would like to reach out to me they can connect with me on my email address frankb@aylward-usa.com
