Particle counter for multilayer coating in-process control
The ICU tablet counter or tablet counting machine utilizes advanced real-time image processing technology to enable highly accurate (100%) counting of tablets in bulk.
Instead of using several narrow tracks that carry one tablet at a time like other tablet counting machines, the image processing technology uses one wide track to count multiple objects such as tablets and capsules, all at once – hence ‘bulk counting.’
Our tablet counters can eliminate the need to separate tablets before counting, feed them one by one or space them out at specific intervals. The result is 3-5 times the output per footprint.
The conceptual difference between the ICU tablet counter and all other tablet counting machines is that it was developed as a technological solution rather than a mechanical one. Counting is carried out by an advanced algorithm developed by a team of highly experienced multi-disciplinary professionals from the fields of electronics, optics, mechanics and computer sciences. This unique collaboration resulted in the emergence of the most advanced counting technology – ‘bulk counting.’
The ICU tablet counter utilizes advanced real-time image processing technology to enable highly accurate (100%) tablet counting and detection in bulk.
The ICU technology of ‘smart’ vision and algorithmic-based counting of tablets, capsules and soft gels, combined with a sophisticated step-motor-driven filling system, can now eliminate your accuracy-related market complaints.
The counting unit is separated from the tracks, which means significantly reduced dust accumulation.
Once dust does accumulates on the counting unit, the system provides an alert. Cleaning takes no more than 15 seconds with no need to disassemble the counting unit which is not a contact part.
All contact parts are designed for tool-free release in accordance with GMP design.
The machine’s small and lightweight parts, the fact that the counting unit is separated from the track, and that contact parts regulation doesn’t apply, resulted in the fastest existing cleaning process.
By using a spare contact part kit, changeover from one product to the next takes no more than 15 minutes, compared minimum 1.5 hours for old generation machines.
Moreover, in-process cleaning is required only once per 8 hours and only in extreme dust conditions.
Feeding the objects on a wide track and the existing filling mechanism enables easy handling and counting of the following: Small objects – as small as 1.8 mm width, flat objects , and oddly shaped objects.
The ICU tablet counter can count any quantity into a bottle, from a single unit and up to infinity.
5-minute changeovers due to lightweight contact parts designed for tool-free release. Tablet data (size, shape, etc.) is learned automatically.
The ICU tablet counter provides broken tablet detection capabilities.
The machine can detect broken pieces as small as 0.5 mm (up to 30% broken piece). Once a rejected tablet is detected, filling of that specific container is halted and the container is immediately sent to the reject station, saving time and money.
It is important to state that the ICU tablet counters are counting machines with embedded detection capabilities, not an inspection system
Automatic product calibration is performed when products are placed on a specifically designed calibration tool, and scanned by the camera. All tablet data (size, shape, etc.) is set automatically, resulting in a very simple and accurate new product setup procedure, avoiding costly human errors.
A single channel consists off our feeders(off the shelf), one electronic board which controls feeds and motor,and two counting heads. This construct entails there is no need for periodic maintenance on a yearly basis, as well as minimal after-sale expenses.
"In the past, we had problems with accuracy when counting small tablets, as well as problems related to powdered and uncoated tablets, the transition to DATA's ICU machine solved all the problems, we are very satisfied."Yongho Lee, Production team head, Korea United Pharm
"When I switched to the DATA's counting machine, there were many concerns because it was a new machine with new and unfamiliar technology, but to my delight, the new machine meets all expectations and gives us higher outputs than the previous machine with better accuracy and almost optimal reliability."Yitzhak Bar Dror, Factory manager, Altman
"In the testing phase of the machine, we sent over 30 different types of the most challenging tablets and capsules: for example, the smallest soft gels, the dirtiest tablets, the most problematic tablets, most of which the previous multichannel machine could not count. The ICU machine can now count all types of tablets, soft gels, and capsules that we pack here while maintaining absolute accuracy."Yitzhak Bar Dror, Factory manager, Altman
"One of the things that we liked about the machine when we first saw it, was that there’s not a lot of parts, so there’s not a lot of stuff to clean. Everything comes apart in seconds really, so if you needed to tear that machine down in under a minute, you could do it."Christopher Baurer, Director of Operations, Proficient Rx
"We have a Tecnomaco Monoblock with a DATA counting machine and we are very pleased. Now we can count tablets and even though a lot of dust is created from the tablets, we can say that the machine counts very accurately. The dust does not interfere, mainly because the camera is positioned separately from the feeding track and tablets."Pietro Carlucci, Director of Production, Kräuterhaus Sanct Bernhard KG
"The service is outstanding, I have a representative who speaks to me in German. I can call at any given moment and the machine can be accessed by remote connection. So far, when I had a problem, I called, and the problem was resolved within a few minutes, I am very pleased with the service."Pietro Carlucci, Director of Production, Kräuterhaus Sanct Bernhard KG
"It was very useful for me in the lab-scale to determine the pellet abrasion."Péter Somogyi pharm D. Formulation Researcher, Teva Pharmaceuticals Industry
"DATA’s ICU 2-80 requires the least setup of anything that sits on the line, so from an overall changeover perspective, the ICU2-80 is very quick. After the initial setup, there is no bottleneck. Once it starts, it counts."Christopher Baurer, Director of Operations, Proficient Rx
"The ICU machines are onetime setting machines. They are "operator friendly" as they can select the recipe of the product directly from the available recipe and start the production."Vikas, maintenance engineer, Hetero
"Now we can certify the real quantity with this machine, for kitting, receiving & verifying the real count of the material. Thank you for putting all of the efforts necessary, to help us with your discovery of this machine, it will bring great accomplishments to our process & efficiency."An International firm from the Electro Mechanical industry
"Teva has purchased the JR-PH counting machine for R&D purpose, we are using it for the last 4 years for counting beads (pellets) which are relatively small objects used in the pharmaceutical industry. It is highly recommended for counting small particles in the same weight & size, which are undergoing the coating process."Gabriel Welber, Russia Project Manager, GGR&D EMIA & APAC, Teva Pharmaceutical Industries
"Previously we would have to choose to run no more than two types of products in a single day, simply because of the time, it would take to manage that machine…. With DATA’s ICU machine we can run double or triple the number of batches of different types of products in a single day."Christopher Baurer, Director of Operations, Proficient Rx