A Recipe for Packaging SuccessA Recipe for Packaging Success

LNK International Inc., one of the nation's largest manufacturers of solid and liquid dose over the counter (OTC) pharmaceuticals, recently expanded its capabilities with a new packaging line for a gastro-intestinal product. Located on Long Island in Hauppauge, NY, this family-owned company produces more than 150 formulas across various categories, including pain relief, cough and cold, and gastro-intestinal treatments. For this latest project, LNK turned to Vac-U-Max to deliver reliable, precise, and efficient bulk powder conveying systems to refill a spindle auger filling machine from Per-Fil Industries.

Managing a Challenging Material

When Mario Mazzella, executive vice president and director of engineering for LNK International Inc., set out to invest in and develop a new packaging line for one of its gastro-intestinal products, he knew it would require more than just standard equipment. The project involved polyethylene glycol (PEG), a challenging, heat-sensitive, and hygroscopic material used in pharmaceuticals and consumer products. To ensure success, Mazzella turned to Vac-U-Max, a trusted partner in bulk powder conveying, to refill a brand-new 4-spindle auger filler from Per-Fil Industries. The new packaging line would be capable of filling multiple-sized plastic bottles with polyethylene glycol, or PEG as it is known in the industry.

Mazzella informed Vac-U-Max  that the new line had to handle multiple bottle sizes, maintain high-speed production, and prevent any product contamination. Their PEG’s properties demanded a closed, precise, and efficient conveying system.  

Polyethylene glycol (PEG) is a versatile compound used in a wide range of consumer products, including skin creams, food additives to prevent foaming, and as a gastro-intestinal aid. However, handling PEG in bulk presents unique challenges due to its waxy, heat-sensitive, and hygroscopic properties. Vac-U-Max and Per-fil Industries recognized these complexities and developed a specialized solution to ensure efficient and safe handling.

Refill conveyor with densifying hopper delivers powders with consistent headload pressure (Vac-U-Max).

The refill solution for this versatile, yet challenging material centers on a vacuum conveyor designed to avoid mechanical contact with the PEG, preventing friction and heat generation that could compromise product integrity. The vacuum conveying system is a closed system from the pickup point to the discharge point, eliminating exposure to moisture which would otherwise cause the PEG to quickly “gum up” the product contact surfaces. An enclosed vacuum conveying system also minimizes fugitive dust--if there are any leaks in the system, it will leak inward--an important feature for any organic dust that can generate a combustible dust condition.

Precision Refill of Auger Fillers

The accuracy and consistency of fill weights are paramount for high-quality packaging operations, ensuring both operational efficiency, consistency, and brand integrity. An imprecise or inconsistent fill, whether underweight, overfilled, or leaving a container or bottle exterior unclean, can lead to dissatisfied customers, who may respond with their purchasing choices or critical reviews on social media.

Shari Becker, president of Per-Fil Industries explained the unique challenges faced by LNK International in developing their new packaging line. “LNK required a machine that would fill bottle sizes ranging from 119 grams up to 578 grams,” she said. “All of the bottles had the same fill opening, so our machine needed to have a widely variable rate. We needed a refill system that would automatically adjust to accommodate whatever rate we were running, from 48-52 bottles per minute (BPM) for the small ones, up to 38 BPM for the large ones. And we needed to accomplish these high rates while keeping the outside of the bottle clean of fugitive dust.”

Achieving these high-performance requirements demanded precise coordination between the auger filler and the refill system, ensuring consistent performance across a range of product sizes while maintaining strict cleanliness standards.

Vacuum Conveyors Enhance Filling Machine Performance

Efficiently refilling packaging machines is a Vac-U-Max specialty. “Our goal in delivering powders to a filling machine is to provide a consistent headload of material to their hopper,” explained Vincent Macaluso, regional sales manager for Vac-U-Max and primary contact for LNK International’s project. “Another way to say it is that we vacuum convey the powder and then densify it in our filling machine adapter before it enters the packaging machine. The filling machine does not even know that the Vac-U-Max conveyor is feeding it.”

This seamless integration is a key advantage, ensuring the auger filler operates efficiently and accurately. As Shari Becker, president of Per-Fil Industries, noted, “The Vac-U-Max conveyor makes our auger filler look like a star, which is exactly what we want from a refill system.”

Powered by a positive-displacement vacuum pump located in a separate room, the Vac-U-Max vacuum conveyor adjusts automatically to match the auger filler’s demands. Whether it is filling four smaller bottles simultaneously at 52 BPM or handling larger bottles with 4X the volume at 38 BPM, the vacuum conveyor is self-adjusting, delivering precise, demand-driven performance that meets the filling rate.

Additionally, the vacuum conveyor with a filling machine adaptor is equipped with its own level probe, eliminating the need for an interconnect with the auger filler under normal circumstances. This simplifies installation, reduces complexity, and ensures easier integration for both installers and operators.

Easy Cleaning with cGMP & FDA Space-Saving Designs

LNK International, a Vac-U-Max customer since 2006, has long relied on multiple vacuum conveying systems for direct-charge loading of tumble blenders and specialized conveyors for loading tablet press machines. When embarking on their polyethylene glycol (PEG) project, LNK prioritized compliance with current Good Manufacturing Practices (cGMP) and stringent FDA standards, focusing on providing the best job for the FDA and their customers.

Sanitation became a key focus early in the engineering phase, prompting Mario Mazzella and Michael Verni of LNK International to visit Vac-U-Max in Belleville, NJ. “Our new equipment will be elevated above a packaging machine. Do you have a design for the vacuum conveyor that will make it easy to clean?” asked Mazzella. Vac-U-Max responded with the ColumnLift accessory that would allow the vacuum conveyor to be lowered to floor level for cleaning in minutes.

ColumnLift makes best use of available ceiling height, while improving serviceability (Vac-U-Max)

“Cleaning at floor level beats cleaning at elevation every time,” said Macaluso. “All of the repair parts, cleaning materials, and tools are also located at ground level, eliminating safety concerns and access challenges associated with using a personnel lift. The ColumnLift footprint is minimal, with a 30-in. circular base on the floor. Even the conveyor controls remain accessible at floor level.”

The vacuum conveyor is easier to clean compared to other conveying technologies. Flexible screws require much more floor space to remove the auger from the tube, and extra care must be given to reach every square inch of product contact surface to meet FDA standards. The vacuum receiver is disassembled without tools, features polished interior surfaces for ease of cleaning, has continuous smooth-ground welds, and soft materials such as filters and gaskets are constructed of FDA-approved materials, ensuring compliance with regulatory standards.

Saving Space and Reducing Operator Strain

Space optimization and worker safety are important concerns for plant managers and project engineers, especially in packaging operations where every square foot matters. The ColumnLift addresses these challenges by eliminating the need for service mezzanines, while utilizing minimal floor space. A simple service platform also requires an access ladder which takes away even more floor space, and mezzanines require headroom for operators to stand up straight, to disassemble the conveyor.

"The ColumnLift takes up minimal floor space, and its design eliminates the need for access ladders and overhead platforms," explained Macaluso. “It only requires a simple disconnect at the discharge end, reducing headroom requirements by 3 to 4 ft.” This design also simplifies maintenance and sanitation tasks. Workers can lower the vacuum conveyor to ground level for cleaning and troubleshooting, removing the need to climb ladders or operate personnel lifts.

For LNK International’s project, where the material is supplied in bulk bags, the ColumnLift offered additional flexibility. “A unique feature of a vacuum conveyor is its ability to draw the ingredient powders directly from any type of container without having to transfer them to some type of intermediate hopper,” says Doan Pendleton, president of Vac-U-Max. “Other powder conveying options, such as flexible screw conveyors, rely on hoppers that need to be loaded which is another material handling step and potential for dust escape.”

Without a mezzanine, workers no longer must climb a ladder to troubleshoot, maintain, or sanitize the powder handling equipment. The combination of the vacuum conveyor and the ColumnLift accessory means that the ingredients can stay at ground level.

At LNK, the PEG was supplied in bulk bags, brought into the processing room on a pallet. Operators use a vacuum wand to extract the PEG from the top fill spout. Minimal operator intervention is needed to reposition the wand. If LNK’s supply of PEG ever changed to fiber drums or totes, the vacuum conveyor will continue to operate without modification.

By simplifying operations, maximizing floor space, and reducing physical strain on operators, the vacuum conveyor and ColumnLift system provide practical, forward-thinking solutions for modern manufacturing challenges. “It’s about making life easier for operators while delivering the reliability and efficiency our customers expect,” said Pendleton.

Vacuum conveyor in operating position, swings away and lowers for sanitation and maintenance (Vac-U-Max).

“Trust But Verify” vs. “Trust Me”

The phrase “trust but verify,” originally a Russian proverb popularized by President Ronald Reagan during US-Soviet relations, holds as much relevance in the world of powder handling. For Vac-U-Max celebrating its 70th year of operation in 2024, and Per-Fil Industries, celebrating 50 years, the adage underscores the importance of testing and verification. 

“Our first effort in the sales process is building confidence by leveraging our experience with over 10,000 different materials,” said Pendleton.

Becker agrees. “Even materials with the same name, such as PEG, may behave differently under differing conditions and applications, depending on how the powder was milled, how long it has been stored in its container, and where it originates from,” Becker said.

“Trust but verify” is practiced by Vac-U-Max and Per-Fil in their customer test labs. LNK International provided test material for Vac-U-Max to confirm the convey rate, reliable discharge, and filtration. Similarly, Per-Fil confirmed the bottle filling rate and cleanliness of the filling process, followed by a Factory Acceptant Test (FAT). Verification at the supplier facility leads to confidence during start-up. “Trust me” leaves the verification until start-up at the customer’s facility.

An important component in the Vac-U-Max customer support system is their local sales representative. Cino Equipment is the local sales representative for LNK International, and they draw on nearly 50 years of powder handling experience, with 36 of those years representing Vac-U-Max. “We sold our first Vac-U-Max equipment to LNK to load their tumble blenders in 1988. A well-experienced rep with a long history with a principal will also contribute to the customer’s confidence,” said Joe Caccamese of Cino Equipment.

This focused, trust-building methodology – testing, verifying, and supporting – ensures that every vacuum conveying system meets customer needs, creating reliability and satisfaction from the beginning. This is not just a philosophy for Vac-U-Max and Per-Fill; it is a proven path to success in dry bulk powder handling.

A Good Customer

LNK International impressed the equipment suppliers as a “good customer.” By providing the necessary test material when requested, visiting the equipment suppliers, and taking responsibility for the system operation, LNK International demonstrated a collaborative approach that ensured success.

LNK prides itself at controlling all aspects of production and packaging of its products. Total control happens in the LNK pharmacy department which blends raw ingredients, both active and inactive. The compression department is where blends are formed into finished single dose products such as tablets and caplets, and the coating department is where tablets are coated using the latest in automated equipment. The encapsulation department transforms blended ingredients into gelcaps, banded and rapid release gelcaps, and capsules.

LNK International’s packaging capabilities include bottling, blistering, pouching, and cartoning. Quality is a full process at LNK International, earning them recognition and awards from major retailers like Walgreens, CVS, Rite Aid, AARP, and others. Working with a customer that values quality and innovation uplifts suppliers as well. “By association with a good customer like LNK International, our good work is being recognized as well,” said Pendleton.

LNK International’s commitment to excellence fosters a mutual understanding and relationship with suppliers like Vac-U-Max and Per-Fil. This collaborative approach ensures that all stakeholders benefit from the “Trust but verify” approach.

For more information about Vac-U-Max call 800-822-8629 or visit www.vac-u-max.com. For more information about Per-Fil Industries Inc. call 856-461-5700 or visit www.per-fil.com.