DIALYZER ASSEMBLY SYSTEM
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DIALYZER ASSEMBLY SYSTEM www.tecnoidealsrl.com 1 TECNOIDEAL SRL – Via Lea Cazzuoli 43 – 41037 MIRANDOLA (MO) - ITAL

Dialyzer assembly system Lay out example

Dialyzer assembly system Tecnoideal has developed a complete assembly system for the production of PS/PES hemodialyzer. Machinery and tools allow a production of 400 dialyzers/hour, based on a continuous process concept. Customized assembly machines are designed for an automated and reliable production process, with a minimal need of manpower. Quality control “in process”, assures complete traceability of each dialyser produced.

Dialyzers configuration: The line processes filters of different sizes (diameters) but of standard length and same connector position. of the filter ports position, allow processing filters with different surfaces  Qick operations of set up on each machine gives flexibility to the filter production line

Preparation for PUR potting of fiber bundles Bundle insertion The preliminar operation the for the potting of the filter heads Manual  Semi-automatic  Automatic Assembly of a potting cap ring by mechanical locking. Operation performed with the pneumatic press In manual or semi-atomatic 100 % inspection of the bundles is possible Plastic sheet removal can be done manually or automatically

Typical assembly operation for PUR potting of hollow fiber filters A- assembly of a potting cap ring B- Inspection and bundle insertion C- Label or data printing D- Laser fiber sealing. E- Potting cap assembly F- Unloading on conveyor buffering for next potting operations.

Filter labelling The filter labelling can be done automatically; the following options are also available: Label printing of the data by using laser technology Temporary traceability laser-engraved on cartridges Automatic label application on filter housing Example of Data printing Variable data (batch and expiration date) are programmed by a PC connected to the laser printer. The system gives the maximum flexibility and the complete traceability of each dialyzer during the pr

Laser beam fiber sealing The head of the bundle is treated with a CO2 laser beam to melt and close the fibers ends Laser fiber sealing is performed by customized programs based on the bundle diameter and fiber material  The laser guarantees a reliable process of fiber end melting to assure proper sealing  Fumes produced in the process are collected by an exhaust system to prevent health hazards and bundle contamination Laser beam chamber connected to fumes removal system

Potting cap assembly Plastic caps can be automatically positioned on filter heads Capping of the potting ring is made by positioning two plastic caps on the filter heads The caps are sorted by feeder bowl and mechanically locked on the plastic ring previously assembled on the filter housing

Potting area A buffer before the potting operation allows the balancing of the machines to prevent unnecessary stocking and trasportation of the filters from one station to the next.

Machine Filter potting with PUR by centrifugation Machine configurations:  Round centrifuges with two filters for each position, on a rotating carousel  The carousel have 16 position for potting. Customized programs can be stored and recalled for a quick set-up of the machine One operator can manage the loading and unloading operations. PUR is injected automatically while the two filters are rotating. Delivery time of the system is about 36 s; 200 dialyzers/h each centrifuge. Total 400 dialy

Mixer for potting with PUR System features:  PUR mixer designed for continuous, reliable work and easy mantainance.  Degassing of PUR components is done continuously. The machine can work three shifts.  Machine refilling with the two component is automatic and based on weighing on board of the component storage  Easy and reliable set-up of the components proportion and qty to dispens

The mixing head uses a static highefficiency mixer.  This avoid to use solvent for cleaning the mixing device.  The mixing operation results cheap and clean.  Customized programs can be stored and recalled for a quick set-up of the machin

The operator loads two filters and a re-usable reservoire in the centrifuge cell The manual loading position has a safety door that remains locked during centrifugation In the next position the mixing head injects the PUR directly in the potting reservoire during rotation. The reservoire distributes the PUR to the four filter heads, dividing the quantity injected in four equal parts. PUR quantity, temperature and centrifugal speed are pre-set paramet

Dialyzers curing buffer Buffering is by a trolley wich holds ab 500 dialyzers awaiting the curing time The dialyzers ready at the pick up point are the first loaded, thus more cured; “fi-fo” system  The trolleys are loaded at the centrifuge station then moved next to the cutting machine for the manual loading of the cutting mach

Cutting and final assembly. The machine performs the following operations:  Removal of the potting cap  First cut or rough cut.  Potting ring removal  Second cut  Final cut  Inspection of filter heads by video camera.  Manual positioning of the “O”ring and blood port  Automatic tightening of the blood ports by torquecontrolled screwing.  Leak testing of the

Caps removal & filter loading First cut Potting ring removal Second cut Third cut Features  Easy handling  Quick and safe operation  Dimensions cm: L 600 ; P 100 ; H 200 Port and “O”ring assembly Port screwing Unloading/reloading to/from P04 Twist lock assembly Finished filter unload

After buffering and curing the dialyzers are ready for the final process The dialyzers are positioned in the loading area by one operator. The loading position, has a buffer of four dialyzers ready to be processed.

Cutting of the filter heads The last cut leaves a smooth head surface cutting operation is performed by diamond-sharpened blades Depending on curing time and hardness of the PUR material the machine can warm the filter head if needed The blade is diamond paste sharpened The thicness of all cuts can be adjusted with high precision by micrometric adjustements