Once serialization lines are up and running, pharma companies face the challenge of managing additional data flows related to the serialization process. Many different code layouts need to be created and archived over a short time period. To make this process more efficient and organised, these layouts require a central management system.
The Layout Software Interface of TQS serialization and aggregation solutions enables connection to any layout management software on the market. Thus, in addition to the possibility of creating different layouts directly on TQS machines, this new feature also allows creation of layouts directly from a desktop computer, via external layout management software. TQS machines can connect to an external layout software via a site management system (L3); the layouts can be stored directly into the Enterprise Resource Planning (ERP) system. The layout software can be any software program that offers complete layout lifecycle control from design and approval to layout production.
LSI offers significant benefits when a company has to create serialization layouts at multiple sites. In this usage case, layout management software can act as the centralised point of access for all authorised users. This thereby allows synchronisation of layouts and templates across different locations. A layout created for a specific pack can be synchronised across all sites, sparing extra time and effort for creating duplicate layouts. This also prevents inconsistency of layout designs at different sites.
Setting up a layout from a desktop computer, you avoid costly machine downtime, needed to create it in the machine interface. The print data is sent to the printer and to the cameras simultaneously. As opposed to other solutions on the market, this uncomplicated process saves you the complex error-prone configuration of the individual units. Thus, the user saves time by working in just one central software. LSI also enables the simultaneous sending of the layouts to the serialization and aggregation machines on all the lines. This spares you redundant layout creation on different lines. LSI allows you to modify an already existing order in a fast and straightforward way. This function is especially important to be agile and react to layout changes as quickly as possible.
In addition to the flexible and intuitive operation with TQS ConfigureFast feature, LSI will optimize the ease of use even more. The image processing units get preset automatically to verify the layouts created in the external layout software. Thus, the print data will be assigned and the image processing task will be set up automatically, sparing the need to teach any subsystem separately. Using layout management software you can significantly reduce complexity when creating layouts and storing them directly in the ERP system. This option is an effective way to manage all layouts centrally and to prevent layout inconsistency and data silos.
Intuitive and ideal to operate, thanks to ConfigureFast, TQS provides the greatest possible flexibility with very easy usage. With ConfigureFast the transport system, coding unit, camera, checkweigher and labeller are controlled from a single software package. For the operator this means convenient set-up and short changeover times on product change during which the usual lengthy changes in several different user interfaces are no longer required. This consistency covers all levels of aggregation.
In TQS, ConfigureFast simultaneously generates content as well as print layout for the required labels. The print data is sent in parallel to the printer and to the image processing unit. This simple operation saves you the usual and sometimes complicated configuration of the various individual units. By means of the print data, the camera already has the accurate pixel information about the printed image. The error-prone method of "teaching“ all the cameras via manually prepared print patterns is completely eliminated. The user saves time by working in just one system, fully integrated and centrally controlled from a touchscreen panel display.
The display gives a clear picture of extensive amounts of information. The user has everything directly in view and can interactively and easily make changes as authorised by the user rights.
ConfigureFast lets you operate and control either our thermal ink jet (TIJ), or the CO₂ laser printer, or the thermal transfer printer (TTO) for the labels. The operator sees no difference in operating the various systems. The print layout is always generated in the simplest way. All of this means that it is very intuitive and easy to configure all of the TQS equipment.
The safe transport of all packages is ensured by the time-tested NT belt technology, which also serves as the basis of high precision weighing. The use of proven modular systems facilitates the implementation of a very broad range of product dimensions.
Designed specifically for the TQS product series, the top belt features continuous height and width adjustments to ensure the safe transfer of the folding boxes and provide the necessary forced guidance. The sprocket belts for the conveyor are coated with a special, high grip rubber surface that provides optimal hold of the packages. Small tolerances are balanced in elevation of the boxes. This construction eliminates slippage and movement of the packages during printing. In addition, this ensures highly accurate printing and verification, which can be increased even more with the aid of an optional synchronization sensor.
No matter what your current IT structure looks like, you must always integrate the required or generated Track & Trace data. The following applies: The lower the number of optional modules to be installed, the better the system will operate.
TQS relies on the use of open XML standard interfaces, avoiding the creation of any proprietary island solutions. The TQS Line Manager gives you the lowest possible IT overhead. The job order data can be input directly into the machine. The Line Manager runs on any TQS module on the line and can easily and conveniently connect to a variety of Level 3 providers.
The core of the Line Manager is the production database which stores the data during the production operations. In the event of a temporary server and network infrastructure failure, the production line is secured by means of a local buffer memory. The permanent data storage is performed only in the Level 3 systems.
All TQS serialization machines (TQS-SP and TQS-HC-A) are designed with a function that checks the print quality of the printed codes in line. This control (grading) takes place continuously during throughput of the packages and is based on ISO/IEC 15415 (for 2D Codes) and 15416 (for 1D Codes).
This evaluation is a good indicator of the print quality and is useful as a trend indicator. In-line grading does not replace the full-scale, standardised verification of the printing results.
A central element of Track & Trace is the traceability of the products based on the serial number. A unique feature of TQS is the acquisition of additional product data beyond the relevant serialization parameters. These include, e.g., the weight and the code quality, which are saved together with the serial number. This additional data can be used in a number of different ways to assess product quality and derive adequate measures.
Remote services in accordance with the highest possible security standards
As it is already the case with consumer goods, machines in pharmaceutical production environment are also subject to the trend towards digitisation and now allow connections to corporate networks and the Internet. For manufacturing pharmaceutical companies, Wipotec provides a secure remote service using the latest IT security standards to perform real-time services remotely. This development offers tremendous opportunities to speed up support service and minimize production downtime.
Full data security due to firewall-based VPN remote service tool
To do this, Wipotec equips all TQS machines with an innovative and firewall-based VPN remote service tool. VPN stands for virtual private network and provides the option of establishing an encrypted connection via the Internet and at the same time guaranteeing data security. Use of the remote service tool increases the efficiency of maintenance and has the advantage of enabling secure remote connection of the TQS machines. The remote service tool integrates seamlessly in existing business IT on the system side. It is designed to protect the customer and ensure overall data integrity.
Only you have control over the scope of service and time of the remote access
Wipotec supports its customers when using the remote service tool by means of a secure smartcard login procedure. The connection is made via a web portal. To switch on the remote service, only your team can enable access to the TQS machine via a hardware switch in the control cabinet. In this way, you always have control over the scope and time of the remote access. A sophisticated security concept ensures that Wipotec can offers you remote services in accordance with the highest security standards.
A key component in meeting European regulations regarding drug safety, is the application of a Tamper-Evident seal on every individual package. The Tamper-Evident seal can be implemented in various ways. The serialization modules TQS-SP and TQS-HC-A use our very compact Tamper-Evident labeler to apply the safety seals. Our unique top belt system gives the necessary support to the packages.
It is necessary in some applications to provide the individual packages with an additional, country-specific label or vignette. This step is also performed in the TQS-SP and TQS-HC-A machines by means of space-saving labeling units. There is an option of using thermal transfer printing facilitates, for example, the flexible printing of batch data.