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Realizing advanced solutions against contaminants in pharmaceutical production

Pharmaceutical metal detector

Anritsu pharmaceutical metal detectors can detect fine metal contaminants in tablets and capsules with the maximum detection sensitivity of a diameter of 0.22 mm (Fe). In a pharmaceutical production line, they can inspect up to 30,000 items per minute.
The equipment can maintain stable detection that is resistant to vibration, electromagnetic noise, and static electricity. Elaborately designed to the finest detail, the detector pursues ease of use.

Pursuing high sensitivity and ease-of-use, and superior stability

Detecting fine metal contaminants with the maximum sensitivity of 0.22 mm diameter

The key to detecting metal contaminants in tablets and capsules with high sensitivity is to create a magnetic field that is optimum for the target pharmaceutical and to properly extract contaminant signals during signal processing.

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Maintains stable detection with resistance against vibration, electromagnetic noise and static electricity

Generally, metal detectors are susceptible to vibrations generated by production line equipment and electromagnetic noise, which impedes the capture of minute signal changes caused by contaminants.
Anritsu metal detectors detect such signals by cancelling these vibrations. They also avoid the effects of noise and frequency interference by digitizing signals, multiplexing frequency channels, and auto-learn settings.

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Elaborately designed to the finest detail, pursuing ease of use

Parts that are in contact with tablets and capsules can be attached and detached without tools, and easily cleaned. Top, bottom, right, and left angular adjustment of the transfer chute is also easily performed without tools. No warm-up is required after starting the machine. There are a wide range of self-monitoring functions including internal state monitoring, duplex monitoring of rejections, and IQ/OQ support.

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Video: Summary (42 seconds)

Detecting fine metal contaminants with the maximum sensitivity of 0.22 mm diameter

Tablets and capsules are relatively small and light targets for a metal detector. The key to detecting metal contaminants with high sensitivity is to create a magnetic field that is optimal for the target pharmaceutical and to properly extract contaminant signals at the signal processing stage.
Anritsu metal detectors feature construction of the detection head, coil winding, and magnetic field frequency that is optimally tuned for target tablets and capsules.
Contaminant signals are extracted from the magnetic field change signals by filtering out the waves that are affected by the targets.

Detection head specially designed for inspecting tablets and capsules
Detection head specially designed for inspecting tablets and capsules

Two points: optimal magnetic field and signal processing
Two points: optimal magnetic field and signal processing

Maintaining stable detection that is resistant to vibration, electromagnetic noise, and static electricity

Vibration

Usually, a metal detector is installed at downstream processing equipment after a tableting machine or a capsule filler in a pharmaceutical production line, where vibrations constantly occur. Improper handling of vibrations could cause false rejection. Anritsu metal detectors control the phase and gain of the noise waves with the proprietary signal processing technologies, which cancel out the vibrations generated by the production line equipment and enables the detection of fine signals from contaminants.

Electromagnetic noise

Production line equipment uses inverters, which generate electromagnetic waves. Again, their improper handling could cause false rejection. Anritsu metal detectors avoid the effects of noise and frequency interference by digitizing signals, multiplexing frequency channels, and auto-learn settings.

Static electricity

Capsules tend to generate static electricity, which adversely affects the operation of the metal detector. Capsules can stick to the chute, preventing smooth flow, which result in rejection failure due to the abnormal rejection timing. Static electricity that has accumulated inside the detector could discharge, which also could result in malfunction. This is why static electricity must be removed. In addition to controlling static electricity by grounding, Anritsu can offer antistatic transport chutes and ionizers as optional solutions.

Maintaining stable detection that is resistant to vibration and electromagnetic noise
Maintaining stable detection that is resistant to vibration and electromagnetic noise

Antistatic design
Antistatic design

Elaborately designed to the finest detail, pursuing ease of use

Cleaning without tools

Parts that are in contact with tablets and capsules (transfer chute, rejection box, and NG bottle), which need to be cleaned every day, can be attached, and detached without tools, and easily cleaned.

Cleaning without tools

Adjustment without tools

Basic adjustment including the chute angle and swing angle do not require tools.

Adjustment without tools

No warm-up is required after starting

After starting, Anritsu metal detectors are ready to operate without requiring a warm-up period.

Intuitive and comprehensive user interface

With the comprehensive user interface, basic operations, settings such as type registration, and responding to error alarms can be performed intuitively.

Intuitive and comprehensive user interface

Validation Support/Fail Safe Function

Anritsu metal detectors have a variety of functions to validate that metal detection has been completed properly.

Constant internal state monitoring

The state inside the metal detector is constantly monitored to avoid operation in an abnormal state. If there is an abnormality in the output from the detection head and balance voltage, an error/alarm screen appears to inform the operator.

Self-diagnosis of detection performance

It is possible to check that the metal detector retains optimal performance when initially installed in the factory by generating a pseudo-NG signal.

Duplex monitoring of rejection gate operation

The position sensors on the OK side and the Non-Good side of the rejection part constantly monitor the rejection operation. It is designed such that when the power fails or an abnormality occurs, the detector always stands by with the rejecter in the Non-Good direction, which is the fail-safe design.

IQ/OQ support function

Anritsu detectors have functions to assist with various verifications including IQ/OQ. It is possible to check the required items using the dedicated sensors and monitor screens.

Constant monitoring of the internal state and duplex monitoring of the rejection operation
Constant monitoring of the internal state and duplex monitoring of the rejection operation

Functions to assist with various validation processes including IQ/OQ
Functions to assist with various validation processes including IQ/OQ

FDA 21 CFR Part 11-compliant Data Integrity Support

Qualified user authentication (user management)

It is necessary to enter the correct user code and password to operate the metal detector. Assigning an access level to each user prevents unauthorized operation.

Audit trail

The history of user operation and machine operation related to production, and the result of checking the operation are internally recorded and the information is made available for monitoring malfunctions and unauthorized operation, analyzing the cause of any problem encountered.

Data encryption and decryption

The data stored in the USB memory is automatically encrypted. To open the encrypted data on a PC, dedicated software (conversion tool) is required to decrypt the data.

Standard Operating Procedure (SOP) Support

The Smart Guide function enables the operator to perform the correct procedures, ensuring SOP.

Model Comparison

High sensitivity model High performance model
Model KDS0902PSW KDS1004PSW
Opening inner diamter 90 mm × 25 mm 100 mm × 40 mm
Chute inner diameter 76 mm × 16 mm 86 mm × 31 mm
Detection sensitivity1 Fe 0.22 mm dia. 0.25 mm dia.
Non-Fe 0.25 mm dia. 0.30 mm dia.
SUS316 0.37 mm dia. 0.40 mm dia.
Product Tablets, soft capsules: thickness of 3 mm or more
Hard capsules: capsule No. 000 to 5
Maximum processing capacity 580,000 capsules/hour (9,700 capsules/min) 1,800,000 capsles/hour (30000 capsules/min)
External dimensions Height: 660 mm to 1080 mm, Width: 550 mm, Depth: 480 mm Height: 660 to 1090 mm, Width: 550 mm, Depth: 480 mm

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