Industry: Pharmaceutical manufacturing (oral solid dosage)
Location: Sector 67, Noida, Uttar Pradesh
Application: Tablet transfer from blister machine to cartonator
Challenge: Manual tablet transfer between blister packaging machine and cartonator was flagged as a contamination control risk in a pre-audit inspection. The client had a GMP audit scheduled in 11 weeks and needed a validated conveyor solution — documented and commissioned — before the audit date.
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THE CHALLENGE
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Manual tablet transfer at this transfer point meant:
• Operator contact with product during every shift
• Particle generation risk from operator clothing and movement
• No audit trail for transfer quantities
• Ergonomic risk to operators handling blisters at awkward height
The client had contacted two other conveyor suppliers. One could not provide IQ/OQ documentation. The other quoted 6 weeks for delivery. With 11 weeks to audit, neither option left sufficient time for validation and commissioning.
Neo Conveyors was contacted on a Thursday. Our senior engineer visited the site on Friday morning.
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NEO CONVEYORS SOLUTION
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We designed and manufactured:
• 1 × flat belt conveyor, 2.8m length × 200mm width
• Frame material: SS 316L, fully TIG welded, mirror-polished on all product contact surfaces
• Belt: 2mm PU FDA-compliant food-grade belt, sealed edges — no fibre exposure
• Drive: 0.37 kW geared motor with single-phase VFD (adjustable 0.1–0.5 m/s)
• Interlocking: Electrical interlock with blister machine (conveyor auto-starts when machine runs, stops when machine stops)
• Enclosure: 3-sided acrylic transparent cover on product transfer section (contamination barrier)
• Legs: Height-adjustable SS 316 levelling feet to match blister machine discharge height exactly
• Documentation package: Installation Qualification (IQ), Operational Qualification (OQ), cleaning validation protocol, material certificates for all SS components, belt compliance certificate
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DELIVERY & INSTALLATION
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• Site visit and design approval: 2 days
• Fabrication: 5 working days
• Dispatch & installation: Day 7
• Commissioning and interlocking with blister machine: Day 8
• Full IQ/OQ documentation package handed over: Day 8
• Total elapsed time from first contact to validated commissioning: 8 working days
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RESULTS — 24 MONTHS AFTER COMMISSIONING
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✅ GMP audit passed with zero observations related to material handling
✅ Zero contamination events recorded in 24 months of production
✅ Manual tablet transfer at this point eliminated 100%
✅ Cleaning validation completed in one cycle — no rework required
✅ Client subsequently ordered 3 additional conveyor lines for other transfer points in the same facility
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CLIENT FEEDBACK
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'We needed a GMP-compliant conveyor in a very short timeframe before a regulatory audit. Neo Conveyors delivered and validated the system in 8 days — including full IQ/OQ documentation. The audit inspector specifically commented positively on the enclosed transfer design. We have since become a regular client.'
— QA Manager, Pharmaceutical Company, Noida
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Need a GMP conveyor with documentation before your next audit?
🌐 https://www.neoconveyors.com/products/modular-slat-chain-conveyor-2
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