The Proslit Eikon slitter/rewinder, installed at the recently expanded Alcan Packaging Pharma Center in Shelbyville, KY, runs materials up to 1,200 mm wide.

Since 1994, the Alcan Packaging Pharma Center is reportedly the only North American facility dedicated to flexible pharmaceutical packaging. With 16 pharma-flexibles facilities operating on three continents, the site is part of an extensive Alcan network that provides optimal product choices for end-user customers. The product range is unmatched in the industry, says Greer, including push-through, peelable, and child-resistant blister-pack lidding, mid- to highest-barrier structures like Polybar® COC, Polybar Aclar®, and Formpack®, sterilizable lidding and pouches, and drug-compliance packaging. 

The crucial slitter/rewinder decision was entrusted to a team of employees who went far afield to specify potential equipment. One trip to Canada and two trips to Spain contributed to the already considerable investment to more than double the Shelbyville Pharma Center production area. Ultimately, the Alcan Packaging team made its final decision on the Proslit Eikon system from Barcelona-based Comexi (www.comexi.com).

Greer recalls, “To spec the new equipment, our team went to Spain twice, first with three employees and then again with four, which was key to the decision making process. The vendor had a showcase operation—everything from a foundry to cast the frames through assembly and shipping and a state-of-the-art showroom. We were able to see the machinery running first-hand and therefore make thoughtful evaluations to be sure that this was the right equipment for our needs.”

The Pharma Center laminates substrates, prints and slits. “We combine several layers and gravure-print them,” explains Greer. “We process material up to 1,200 mm wide and finish slit to customer requirements. Our challenge was not only to increase capacity, but rather to meet the very tight tolerances requested by our customers.”

When the delivery came [in fall 2006], the Alcan Packaging team waited on installation until the new finishing room was complete. “We have created an environment for the finishing area that was based on historic feedback from our customers,” says Greer. “Pharma customers intend for our products to be provided in a fit-for-use condition. We have been able to meet those standards by managing the environment within our operation.”

The Comexi and Alcan Packaging technical teams were able to examine the market needs of the core products and “design in” features with the slitter that would allow Alcan Packaging to meet or improve the technical service requirements of their markets. The design teams achieved this through the machine construction tolerances as well as with complimentary optional equipment that was added on to the slitter. The new optional equipment has been validated to meet the strict technical requirements of the pharma products run at the Alcan site. It also allows them to be in a successful market position with these product platforms for years to come.

The Proslit Eikon is a welcome asset that complements Alcan Packaging's schedule, and operators appreciate the additional automated functions. Following nearly two weeks training, they also enjoy the nonstop production capabilities. “With the Proslit Eikon, an operator can finish up a project and just hit a start button and go,” says Greer.

With more than 150 Pharma Center employees in Shelbyville, Greer says he is proud of the staff and their knowledge of the industry. “The Alcan Packaging Pharma Center team selected the best machine for our application. Their efforts to make it a success are obvious, and it is another example of how we use operational, people, and supply-chain excellence.”