HIGH-PRECISION TRAY FILLING SYSTEM FOR PHARMACEUTICAL PACKAGING

Abstract

ABSTRACT High-Precision Tray Filling System for Pharmaceutical Packaging The present disclosure introduces a high-precision tray filling system 100 for pharmaceutical packaging which ensures contamination-free filling of pharmaceutical products. The system integrates a product hopper and adaptive feeder mechanism 102 for regulated product flow, a dosing unit with dual-sensor monitoring 104 for precise dosage delivery, and a robotic arm for multi-axis tray handling 106 to position, fill, and eject trays. A contamination control system 108 maintains a sterile environment, while a precision alignment and vision system 110 ensures real-time tray alignment. Non-contact laser measurement system 114 validates fill levels, and a configurable multi-lane filling mechanism 116 allows high-speed filling of multiple tray rows. Additional components are vacuum-assisted product placement system 118, IoT-enabled monitoring and control system 120, user interface and control software 122, error detection and smart fault recovery mechanism 124, anti-static and moisture control features 126, and advanced compliance reporting system 140. Reference Fig 1

Specification

Description:
High-Precision Tray Filling System for Pharmaceutical Packaging
TECHNICAL FIELD
[0001] The present innovation relates to automated pharmaceutical packaging systems, specifically a high-precision tray filling system for accurately dosing and placing pharmaceutical products into trays while minimizing contamination and wastes.

BACKGROUND

[0002] Pharmaceutical packaging, particularly for solid dosage forms like tablets and capsules, is a critical process that directly impacts product quality, patient safety, and regulatory compliance. However, existing tray filling systems face significant challenges, including inaccuracies in dosing, contamination risks, inefficiency, and difficulty integrating into modern high-speed production lines. Conventional systems often result in overfills or underfills, leading to wastage, non-compliance with dosage regulations, and higher chances of product recalls. These errors increase operational costs and compromise product integrity. Moreover, many traditional systems rely on manual intervention or rudimentary automation, which increases contamination risks, particularly in sterile environments, and limits scalability and flexibility.

[0003] To address these challenges, options like semi-automated tray fillers and high-speed fillers with basic sensor integration are available. While these systems offer improvements in speed and some level of automation, they often lack the precision, contamination control, and adaptability required for modern pharmaceutical manufacturing. Additionally, they do not effectively minimize waste or integrate seamlessly with other advanced packaging systems.


[0004] The High-Precision Tray Filling System for Pharmaceutical Packaging stands apart from existing options by incorporating advanced sensors, robotic mechanisms, and intelligent software to deliver exceptional accuracy, efficiency, and contamination control. The invention uses dual-sensor technology for real-time monitoring, ensuring precise dosing in each tray cavity. Features like a sealed, HEPA-filtered environment, clean-in-place technology, and adaptive robotic arms eliminate contamination risks and reduce manual intervention. The system's modular and flexible design allows it to integrate seamlessly with existing production lines, accommodating diverse product types and tray configurations.

[0005] Novel features such as vision-assisted alignment, vacuum-assisted product placement, and IoT-enabled remote monitoring ensure unparalleled accuracy, operational efficiency, and compliance with stringent regulatory standards. By addressing the limitations of conventional systems, this invention offers a transformative solution for pharmaceutical manufacturers, ensuring sustainable and high-quality production practices.

OBJECTS OF THE INVENTION

[0006] The primary object of the invention is to enhance pharmaceutical manufacturing precision by providing real-time adaptive control over critical production parameters.

[0007] Another object of the invention is to improve product consistency and quality by automatically adjusting process variables based on real-time data.

[0008] Another object of the invention is to reduce material waste and energy consumption, contributing to more sustainable and environmentally responsible manufacturing practices.

[0009] Another object of the invention is to minimize production downtime by predicting potential issues and proactively adjusting parameters to maintain optimal operating conditions.

[00010] Another object of the invention is to ensure regulatory compliance by automating documentation and traceability, simplifying audits and inspections in highly regulated environments.
[00011] Another object of the invention is to enable seamless integration across multiple stages of pharmaceutical manufacturing, such as formulation, mixing, and packaging, through a modular and scalable design.

[00012] Another object of the invention is to provide a self-learning system that improves predictive accuracy over time, enhancing its ability to adapt to changing production conditions.

[00013] Another object of the invention is to offer manufacturers a cost-effective solution for optimizing large-scale production processes by reducing operational inefficiencies and resource usage.

[00014] Another object of the invention is to enhance operational transparency by providing a user interface that allows real-time monitoring and manual override options for operators.

[00015] Another object of the invention is to support continuous manufacturing processes by enabling real-time adjustments, which promote consistent and efficient production flow without interruption.

[00016] The primary object of the invention is to enhance the accuracy of pharmaceutical packaging by providing a high-precision tray filling system that ensures consistent dosing and placement of pharmaceutical products.
[00017] Another object of the invention is to reduce product wastage by employing advanced sensors and real-time monitoring mechanisms to prevent overfilling or underfilling of tray cavities.

[00018] Another object of the invention is to minimize contamination risks during the tray filling process by incorporating a sealed environment with HEPA-filtered airflow and clean-in-place technology.

[00019] Another object of the invention is to improve operational efficiency and throughput by automating tray handling, alignment, and filling with robotic arms and precision alignment systems.

[00020] Another object of the invention is to provide a flexible and scalable solution that can accommodate various tray sizes, product types, and configurations, making it adaptable for diverse pharmaceutical manufacturing needs.

[00021] Another object of the invention is to ensure compliance with regulatory standards, such as Good Manufacturing Practices (GMP), by incorporating features like real-time error detection, automated rejection mechanisms, and detailed traceability.

[00022] Another object of the invention is to integrate seamlessly with existing pharmaceutical packaging lines, enabling easy adoption without significant modifications to current production workflows.

[00023] Another object of the invention is to promote sustainable manufacturing practices by reducing waste, optimizing resource utilization, and employing energy-efficient components.

[00024] Another object of the invention is to enhance user control and monitoring by providing an intuitive interface, customizable control software, and IoT-enabled remote access for real-time system oversight.

[00025] Another object of the invention is to improve reliability and reduce downtime through predictive maintenance alerts and smart fault recovery mechanisms, ensuring uninterrupted high-speed operation.

SUMMARY OF THE INVENTION

[00026] In accordance with the different aspects of the present invention, high-precision tray filling system for pharmaceutical packaging is presented. The invention ensures accurate dosing, minimizes contamination, and enhances operational efficiency. It integrates advanced sensors, robotic arms, and intelligent software for seamless tray handling and real-time error detection. The system operates in a sealed, HEPA-filtered environment with clean-in-place technology to meet stringent regulatory standards. Its flexible, scalable design supports various tray sizes and product types, while IoT-enabled monitoring ensures optimal performance. This innovative solution reduces waste, improves compliance, and promotes sustainable pharmaceutical manufacturing.

[00027] Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.

[00028] It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

BRIEF DESCRIPTION OF DRAWINGS
[00029] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

[00030] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

[00031] FIG. 1 is component wise drawing for high-precision tray filling system for pharmaceutical packaging.

[00032] FIG 2 is working methodology of high-precision tray filling system for pharmaceutical packaging.

DETAILED DESCRIPTION

[00033] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.

[00034] The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of high-precision tray filling system for pharmaceutical packaging and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[00035] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[00036] The terms "comprises", "comprising", "include(s)", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by "comprises... a" does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

[00037] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration-specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

[00038] The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.

[00039] Referring to Fig. 1, high-precision tray filling system for pharmaceutical packaging 100 is disclosed in accordance with one embodiment of the present invention. It comprises of product hopper and adaptive feeder mechanism 102, dosing unit with dual-sensor monitoring 104, robotic arm for multi-axis tray handling 106, contamination control system 108, precision alignment and vision system 110, tray ejection and automated sorting mechanism 112, non-contact laser measurement system 114, configurable multi-lane filling mechanism 116, vacuum-assisted product placement system 118, iot-enabled monitoring and control system 120, user interface and control software 122, error detection and smart fault recovery mechanism 124, anti-static and moisture control features 126, dynamic product recognition system 128, integrated reject bin 130, variable-speed drive 132, advanced sorting and tray recognition system 134, energy-efficient operation 136, environmentally conscious materials 138, advanced error logging and compliance reporting 140, smart fault recovery and auto-restart 142.

[00040] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with product hopper and adaptive feeder mechanism 102, which holds bulk quantities of pharmaceutical products and ensures a consistent flow to the dosing unit. The vibration-controlled feeder adjusts its intensity dynamically based on the product type, enabling smooth movement of tablets or capsules. This component works in tandem with dosing unit 104 to ensure accurate delivery and prevents blockages, enhancing operational efficiency. The hopper is constructed with food-grade materials to maintain product safety and integrity.
[00041] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with dosing unit with dual-sensor monitoring 104, which utilizes high-precision load cells and optical sensors for real-time accuracy during the filling process. It ensures that each tray cavity receives the exact dosage while immediately halting the process if discrepancies are detected. The dosing unit collaborates seamlessly with precision alignment and vision system 110 to ensure perfect placement of products in each cavity. It also interacts with tray ejection and automated sorting mechanism 112 to flag and reject defective trays.

[00042] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with robotic arm for multi-axis tray handling 106, which automates the handling of trays, including their positioning, filling, and ejection. The robotic arm's multi-axis design accommodates various tray sizes and shapes with high precision. It integrates closely with contamination control system 108 to operate in a sterile environment, minimizing contamination risks. The robotic arm also works in synchronization with configurable multi-lane filling mechanism 116 to optimize throughput for high-volume production.

[00043] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with contamination control system 108, which creates a sealed environment for the filling process, equipped with HEPA-filtered airflow to eliminate particulate contamination. The system incorporates clean-in-place technology to automate sterilization without disassembly, ensuring compliance with pharmaceutical safety standards. This component operates alongside vacuum-assisted product placement system 118 to maintain sterility during delicate handling of products. It also enhances the reliability of non-contact laser measurement system 114 by ensuring a clean environment for precise measurements.

[00044] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with precision alignment and vision system 110, which uses computer vision technology to detect and correct tray misalignments in real-time. It ensures that every tray cavity is properly aligned beneath the dosing unit 104 for precise filling. This component also interacts with dynamic product recognition system 128 to adapt to variations in product size or shape. By maintaining alignment, it improves the overall accuracy and efficiency of the tray filling process.

[00045] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with tray ejection and automated sorting mechanism 112, which ensures quality control by sorting compliant trays for further processing and rejecting defective trays. This component works in close coordination with dosing unit with dual-sensor monitoring 104 to detect underfills, overfills, or contamination. The mechanism includes a contaminant detection feature that redirects trays with foreign particles to an integrated reject bin 130. This ensures that only fully compliant trays proceed to the packaging stage, maintaining product quality and regulatory compliance.

[00046] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with non-contact laser measurement system 114, which validates the fill levels in each tray cavity using laser technology. This non-invasive system scans each cavity without touching the product, ensuring precise measurements while maintaining sterility. The laser measurement system complements the dosing unit with dual-sensor monitoring 104 for enhanced accuracy and works in conjunction with contamination control system 108 to minimize environmental interference during measurements.

[00047] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with configurable multi-lane filling mechanism 116, which allows simultaneous filling of multiple rows of trays, significantly increasing production throughput. The mechanism can be adjusted independently for different tray configurations, making it adaptable for diverse manufacturing needs. It integrates with robotic arm for multi-axis tray handling 106 to ensure proper alignment and efficient operation. This flexibility makes it ideal for high-volume production lines requiring quick transitions between product types.

[00048] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with vacuum-assisted product placement system 118, which gently handles delicate or irregularly shaped pharmaceutical products during the filling process. This system minimizes mechanical impact, ensuring the structural integrity of fragile products such as soft gels or coated tablets. It works closely with contamination control system 108 to maintain sterility during product handling and with precision alignment and vision system 110 for accurate placement.

[00049] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with iot-enabled monitoring and control system 120, which enables remote monitoring and diagnostics through a secure cloud interface. This system collects real-time data from all components, such as dosing unit with dual-sensor monitoring 104 and precision alignment and vision system 110, to optimize performance and identify potential issues. It also provides predictive insights and maintenance alerts, ensuring uninterrupted operation and efficient resource management.

[00050] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with user interface and control software 122, which allows operators to configure parameters, monitor real-time performance, and log production data. The software works closely with iot-enabled monitoring and control system 120 to provide actionable insights and alerts. It also interacts with error detection and smart fault recovery mechanism 124 to ensure seamless operations by notifying operators of system interruptions and guiding corrective actions.

[00051] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with error detection and smart fault recovery mechanism 124, which identifies process interruptions, such as product jams or misalignments, and performs automated corrective actions. This component collaborates with precision alignment and vision system 110 and tray ejection and automated sorting mechanism 112 to ensure that errors are promptly resolved without halting the production line. If necessary, it triggers safe mode operation and auto-restart functionality to resume from the point of interruption.

[00052] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with anti-static and moisture control features 126, which prevent issues such as product clumping or sticking due to static electricity or moisture. These features ensure smooth product flow in coordination with product hopper and adaptive feeder mechanism 102 and maintain optimal conditions for handling sensitive pharmaceuticals. The anti-static measures also protect the integrity of electronic components, such as non-contact laser measurement system 114, during operation.

[00053] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with dynamic product recognition system 128, which uses AI algorithms to detect variations in size, shape, and color of pharmaceutical products. This system allows seamless handling of multiple product types on a single production line. It integrates with precision alignment and vision system 110 to ensure accurate placement and with configurable multi-lane filling mechanism 116 to adapt filling parameters dynamically based on product characteristics.

[00054] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with integrated reject bin 130, which collects trays rejected due to errors or contamination during the quality control process. This component works closely with tray ejection and automated sorting mechanism 112 to ensure defective trays are separated efficiently from compliant ones. It also supports contaminant detection features of contamination control system 108, preventing compromised trays from proceeding further in the production line.
[00055] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with variable-speed drive 132, which dynamically adjusts the speed of the filling process based on real-time data inputs, such as product type and error rates. This system ensures a balance between production speed and precision. It operates in coordination with product hopper and adaptive feeder mechanism 102 to maintain smooth product flow and with dosing unit with dual-sensor monitoring 104 for accurate filling at high speeds.

[00056] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with advanced sorting and tray recognition system 134, which identifies different tray configurations and automatically adjusts system operations accordingly. This feature reduces setup time during product transitions and ensures seamless operation. It interacts with robotic arm for multi-axis tray handling 106 and precision alignment and vision system 110 to maintain accuracy and efficiency during the sorting and filling process.

[00057] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with energy-efficient operation 136, which minimizes power consumption using optimized motors and components. This feature aligns with sustainable manufacturing practices while ensuring high throughput. It enhances the performance of components such as robotic arm for multi-axis tray handling 106 and configurable multi-lane filling mechanism 116, ensuring energy efficiency without compromising functionality.

[00058] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with environmentally conscious materials 138, which are eco-friendly and recyclable, reducing the system's overall environmental impact. These materials are used in key components such as product hopper and adaptive feeder mechanism 102 and contamination control system 108, ensuring sustainability without compromising durability or performance.

[00059] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with advanced error logging and compliance reporting 140, which records all process errors, contamination incidents, and operational data for audit and compliance purposes. This component works with iot-enabled monitoring and control system 120 to generate detailed reports for regulatory bodies, ensuring full traceability and quality assurance throughout the production process.

[00060] Referring to Fig. 1, the high-precision tray filling system for pharmaceutical packaging 100 is provided with smart fault recovery and auto-restart 142, which detects faults, such as misalignments or product jams, and performs corrective actions without halting production. This system integrates with error detection and smart fault recovery mechanism 124 to ensure efficient fault management. If necessary, it restarts operations from the point of interruption, minimizing downtime and production losses.

[00061] Referring to Fig 2, there is illustrated method 200 for high-precision tray filling system for pharmaceutical packaging 100. The method comprises:
At step 202, method 200 includes pharmaceutical products being loaded into the product hopper and adaptive feeder mechanism 102, where the vibration-controlled feeder ensures a consistent and regulated flow of products based on their size and type;
At step 204, method 200 includes products being directed to the dosing unit with dual-sensor monitoring 104, where weight and physical placement are monitored in real-time by load cells and optical sensors;
At step 206, method 200 includes trays being picked from the stack and positioned under the dosing unit 104 by the robotic arm for multi-axis tray handling 106, ensuring alignment with the help of the precision alignment and vision system 110;
At step 208, method 200 includes the dosing unit 104 dispensing the exact quantity of pharmaceutical products into each cavity of the tray, monitored by the sensors;
At step 210, method 200 includes the non-contact laser measurement system 114 scanning each cavity after filling to validate the fill levels for accuracy without physically contacting the product;
At step 212, method 200 includes the contamination control system 108 maintaining a sealed and sterile environment using HEPA-filtered airflow and optional tray sterilization before filling;
At step 214, method 200 includes the precision alignment and vision system 110 making any necessary real-time adjustments to the tray's position to ensure accurate filling;
At step 216, method 200 includes the configurable multi-lane filling mechanism 116 enabling simultaneous filling of multiple rows of trays to maximize production throughput;
At step 218, method 200 includes trays being transferred to the tray ejection and automated sorting mechanism 112, where quality control checks identify defects such as overfills, underfills, or contaminants;
At step 220, method 200 includes defective trays being directed to the integrated reject bin 130 for reprocessing or disposal, while compliant trays proceed further in the workflow;
At step 222, method 200 includes dynamic product recognition system 128 detecting variations in product size, shape, or color and adapting system operations accordingly for seamless handling;
At step 224, method 200 includes the vacuum-assisted product placement system 118 gently handling fragile or irregularly shaped products to ensure structural integrity during the filling process;
At step 226, method 200 includes the anti-static and moisture control features 126 preventing issues like clumping or static adherence, ensuring smooth handling of moisture-sensitive products;
At step 228, method 200 includes the variable-speed drive 132 dynamically adjusting the speed of the process based on real-time data, such as product flow and error rates;
At step 230, method 200 includes energy-efficient operation 136 optimizing power usage throughout the system, minimizing energy consumption while maintaining high throughput;
At step 232, method 200 includes environmentally conscious materials 138 ensuring sustainable operation by using recyclable and eco-friendly components across all key systems;
At step 234, method 200 includes the advanced error logging and compliance reporting system 140 recording all operational data, including errors and maintenance events, for audit trails and regulatory compliance;
At step 236, method 200 includes the iot-enabled monitoring and control system 120 providing real-time data analytics, remote management, and predictive maintenance alerts to operators;
At step 238, method 200 includes the user interface and control software 122 enabling operators to configure parameters, monitor performance, and make adjustments as needed based on production requirements;
At step 240, method 200 includes smart fault recovery and auto-restart 142 detecting process interruptions such as jams or misalignments, performing corrective actions, and resuming operations without halting production.
[00062] The high-precision tray filling system for pharmaceutical packaging 100 offers numerous advantages that enhance efficiency, accuracy, and sustainability in pharmaceutical manufacturing. The product hopper and adaptive feeder mechanism 102 ensures consistent flow and prevents blockages, while the dosing unit with dual-sensor monitoring 104 delivers precise dosages with real-time error detection, reducing wastage and ensuring compliance with regulatory standards. The robotic arm for multi-axis tray handling 106 and precision alignment and vision system 110 automate tray handling and alignment, minimizing manual intervention and increasing throughput. The contamination control system 108, coupled with HEPA-filtered airflow and clean-in-place technology, maintains sterility throughout the process, ensuring product safety. The non-contact laser measurement system 114 validates fill levels without physical contact, preserving product integrity. With the configurable multi-lane filling mechanism 116, high-speed production is achieved while maintaining flexibility for varying tray sizes. Additionally, the IoT-enabled monitoring and control system 120 provides real-time analytics, predictive maintenance, and remote management, enhancing operational efficiency. The integration of energy-efficient operation 136 and environmentally conscious materials 138 further supports sustainable practices, making this system an innovative and reliable solution for pharmaceutical packaging.

[00063] In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms "fixed" "attached" "disposed," "mounted," and "connected" are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.

[00064] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.

[00065] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
, Claims:WE CLAIM:
1. A high-precision tray filling system for pharmaceutical packaging 100 comprising of
data acquisition module 102 to collect real-time data from sensors across the manufacturing environment;
data filtering and normalization system 104 to remove noise and standardize data for accurate analysis;
predictive analytics engine 106 to analyze trends and predict potential deviations in production parameters;
process optimization algorithms 108 to calculate optimal adjustments for manufacturing parameters;
root cause analysis module 110 to identify causes of detected deviations or anomalies in production;
real-time parameter control system 112 to implement adjustments in parameters like temperature and pressure;
closed-loop feedback system 114 to monitor the effects of adjustments and refine settings as needed;
adaptive learning mechanism 116 to improve predictive accuracy using historical data and past adjustments;
user interface with manual override 118 to allow operators to monitor data and intervene if necessary;
automated documentation system 120 to record all adjustments and deviations for regulatory compliance;
traceability engine 122 to create a full production history for each batch for quality tracking;
compliance rule engine 124 to automate regulatory documentation and ensure standards are met;
energy and resource analytics dashboard 126 to provide insights on resource consumption and efficiency;
machine health monitoring system 128 to assess equipment performance and detect early signs of wear;
predictive maintenance algorithms 130 to forecast maintenance needs based on equipment condition;
continuous manufacturing integration module 132 to enable real-time adjustments for continuous production;
sensor calibration system 134 to automatically calibrate sensors for consistent measurement accuracy;
batch-to-batch optimization feature 136 to adjust settings for subsequent batches based on prior runs;
environmental impact minimization module 138 to monitor and adjust processes to reduce environmental impact;
in-line product quality prediction and grading module 140 to continuously assess product quality during production;
modular system architecture for adaptability 142 to support easy scaling and integration with new components;
customizable parameter adjustment algorithms 144 to allow optimization specific to each product;
dynamic sensitivity adjustment module 146 to adjust control sensitivity for critical manufacturing steps;
data redundancy and fault tolerance system 148 to ensure reliable data through cross-referenced sensor inputs;
pk/pd integration module 150 to align manufacturing parameters with pharmacokinetic and pharmacodynamic models;
smart resource allocation system 152 to optimize resource usage based on real-time production demand;
context-aware scheduling module 154 to adjust production schedules based on external factors;
cross-site synchronization module 156 to ensure uniform quality across global manufacturing locations;
api yield optimization module 158 to maximize active pharmaceutical ingredient yield through real-time adjustments;
product hopper and adaptive feeder mechanism 102 to regulate the flow of pharmaceutical products with vibration-controlled precision;
dosing unit with dual-sensor monitoring 104 to ensure accurate dosage and placement in tray cavities;
robotic arm for multi-axis tray handling 106 to position, fill, and eject trays with high precision;
contamination control system 108 to maintain a sterile environment using hepa-filtered airflow;
precision alignment and vision system 110 to ensure real-time tray alignment for accurate product placement;
tray ejection and automated sorting mechanism 112 to separate compliant trays from defective ones;
non-contact laser measurement system 114 to validate fill levels without contacting the product;
configurable multi-lane filling mechanism 116 to enable high-speed filling of multiple tray rows simultaneously;
vacuum-assisted product placement system 118 to handle fragile products gently and securely;
iot-enabled monitoring and control system 120 to provide real-time data analytics and remote management;
user interface and control software 122 to configure parameters and monitor the tray filling process;
error detection and smart fault recovery mechanism 124 to identify and correct process interruptions automatically;
anti-static and moisture control features 126 to prevent product clumping and ensure smooth operation;
dynamic product recognition system 128 to detect variations in product size, shape, or color;
integrated reject bin 130 to collect trays rejected due to errors or contamination;
variable-speed drive 132 to adjust the system speed dynamically based on real-time inputs;
advanced sorting and tray recognition system 134 to adapt to different tray configurations seamlessly;
energy-efficient operation 136 to minimize power consumption while maintaining high throughput;
environmentally conscious materials 138 to ensure sustainable operation with recyclable components;
advanced error logging and compliance reporting system 140 to record all operational data for regulatory compliance;
smart fault recovery and auto-restart 142 to detect and resolve faults while resuming operations efficiently.
2. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein product hopper and adaptive feeder mechanism 102 is configured to regulate the flow of pharmaceutical products using a vibration-controlled feeder that dynamically adjusts intensity based on product size and type, ensuring consistent delivery and preventing blockages.

3. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein dosing unit with dual-sensor monitoring 104 is configured to deliver precise dosages into tray cavities by integrating load cells and optical sensors for real-time monitoring, enabling immediate error detection and correction for enhanced accuracy.

4. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein robotic arm for multi-axis tray handling 106 is configured to handle trays with high precision, including positioning, filling, and ejection, using multi-axis movement and seamless integration with vision-based alignment for diverse tray configurations.

5. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein contamination control system 108 is configured to maintain a sterile and sealed environment with HEPA-filtered airflow and clean-in-place technology, ensuring compliance with stringent pharmaceutical safety standards.

6. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein precision alignment and vision system 110 is configured to detect and correct tray misalignments in real time using computer vision technology, ensuring accurate placement of pharmaceutical products with minimal manual intervention.

7. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein non-contact laser measurement system 114 is configured to validate fill levels in tray cavities using non-invasive laser technology, ensuring precise volume measurements without physical contact to preserve product integrity.

8. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein configurable multi-lane filling mechanism 116 is configured to enable simultaneous filling of multiple rows of trays, increasing production throughput while maintaining flexibility to handle varying tray sizes and product types.

9. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein IoT-enabled monitoring and control system 120 is configured to provide real-time data analytics, predictive maintenance alerts, and remote management capabilities, ensuring efficient and uninterrupted system performance across production workflows.


10. The high-precision tray filling system for pharmaceutical packaging 100 as claimed in claim 1, wherein method comprises of
pharmaceutical products being loaded into the product hopper and adaptive feeder mechanism 102, where the vibration-controlled feeder ensures a consistent and regulated flow of products based on their size and type;
products being directed to the dosing unit with dual-sensor monitoring 104, where weight and physical placement are monitored in real-time by load cells and optical sensors;
trays being picked from the stack and positioned under the dosing unit 104 by the robotic arm for multi-axis tray handling 106, ensuring alignment with the help of the precision alignment and vision system 110;
dosing unit 104 dispensing the exact quantity of pharmaceutical products into each cavity of the tray, monitored by the sensors;
non-contact laser measurement system 114 scanning each cavity after filling to validate the fill levels for accuracy without physically contacting the product;
contamination control system 108 maintaining a sealed and sterile environment using hepa-filtered airflow and optional tray sterilization before filling;
precision alignment and vision system 110 making any necessary real-time adjustments to the tray's position to ensure accurate filling;
configurable multi-lane filling mechanism 116 enabling simultaneous filling of multiple rows of trays to maximize production throughput;
trays being transferred to the tray ejection and automated sorting mechanism 112, where quality control checks identify defects such as overfills, underfills, or contaminants;
defective trays being directed to the integrated reject bin 130 for reprocessing or disposal, while compliant trays proceed further in the workflow;
dynamic product recognition system 128 detecting variations in product size, shape, or color and adapting system operations accordingly for seamless handling;
vacuum-assisted product placement system 118 gently handling fragile or irregularly shaped products to ensure structural integrity during the filling process;
anti-static and moisture control features 126 preventing issues like clumping or static adherence, ensuring smooth handling of moisture-sensitive products;
variable-speed drive 132 dynamically adjusting the speed of the process based on real-time data, such as product flow and error rates;
energy-efficient operation 136 optimizing power usage throughout the system, minimizing energy consumption while maintaining high throughput;
environmentally conscious materials 138 ensuring sustainable operation by using recyclable and eco-friendly components across all key systems;
advanced error logging and compliance reporting system 140 recording all operational data, including errors and maintenance events, for audit trails and regulatory compliance;
iot-enabled monitoring and control system 120 providing real-time data analytics, remote management, and predictive maintenance alerts to operators;
user interface and control software 122 enabling operators to configure parameters, monitor performance, and make adjustments as needed based on production requirements;
smart fault recovery and auto-restart 142 detecting process interruptions such as jams or misalignments, performing corrective actions, and resuming operations without halting production.

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