Medical Manufacturing: Ways to Improve Fluid Dispensing Control - Part Four

Part Four: Dispensing Dots and Lines

Part one, two, and three of this series explored spraying and coating, filling, and bonding. In this final part, we will discuss efficient techniques for dispensing dots and lines in medical device manufacturing.

You’ll notice a central theme throughout this four-part series. It is the importance of remembering that sometimes small changes can make a big difference, especially when it comes to the fluid dispensing equipment you use in your manufacturing process. Read on to learn more.

Dispensing Dots and Lines

From a slow cycle rate to a faster cycle rate

Sometimes you can increase throughput by making one small change. A medical device manufacturer who switched to dispense valves with a unique BackPack valve actuator for dispensing lines in a solvent bonding application achieved a 30% increase in production speed.

Installing the BackPack, which is a small, fast-acting solenoid that mounts directly onto the valve, allows the dispense valve to achieve actuation speeds as fast as 5 to 6 milliseconds. This allows for faster cycle rates up to 80 fluid deposits per second.

After the higher-cycle-rate valves were installed, the production line dispensed more fluid deposits in a shorter amount of time, therefore increasing output per unit of time. What previously took 30 seconds now takes 20 seconds. Switching to the right valves with BackPack actuators is an easy way to increase throughput without compromising dispensing integrity.

In fact, the BackPack actually reduces the possibility of deposit size variation due to fluctuating plant air pressures or different air hose lengths. Since control of the open and close time is at the valve, you can expect more consistent dispensing results.

Key takeaway: You do not always need to make a significant, costly change to obtain a significant benefit. Sometimes one small change can make a big difference.

Nordson EFD Solutions: xQR41 MicroDot needle valves with BackPack actuators

From a hard-to-use dispensing needle to a high-pressure device

Optimization does not always mean switching from a manual to an automated process. In this example, a medical device manufacturer had to backfill a very thick material through a very thin tube. It was a challenge that required a lot of manual force and exposed the operators to repetitive motions and ergonomic issues.

When the manufacturer switched to a high-pressure handheld dispensing device, they eliminated multiple problems: the risk of operator injury due to repetitive motion and poor ergonomics, slow production times, application inconsistencies, and poor product quality.

Key takeaway: Do not assume that a manual process can only be improved by advancing to an automated process. Advances in dispensing methodologies apply to manual dispensing as well.

Nordson EFD Solutions: HPx high-pressure dispensing tools

From irregular beads and dots to perfect beads and dots

When a vaccine manufacturer switched to jetting technology for the application of beads and paint dots on ampoules, they reduced their reject rate by 60%. Because the visible beads and dots indicate what material is inside an ampoule, clarity is critical.

With the old method, the beads were either too thick, too thin, or overlapped, and the dots of paint were too big or too small. Sometimes the beads or dots were dragged across the surface, rendering the product unusable.

Jetting technology was ideal for improving this application because it eliminated surface contact. When you want to dispense precise sizes of beads or dots of fluid onto an extremely specific spot on a surface, then non-contact dispensing is the obvious solution. Jetting technology provides repeatability — the exact same deposit time after time in the correct place time after time.

Key takeaway: For your contact dispensing applications, ask yourself if switching to a non-contact jetting process would eliminate costly application problems.

Nordson EFD Solutions: PICO Pµlse jetting systems

Summary

Use the many examples provided in this series to think about your own manufacturing floor. Walk around and cast a critical and attentive eye on each part of a production process. When you do make a change, choose a technique that is flexible enough to adapt to future process changes, and always consider the total cost of ownership, not just the up-front costs.

If you have any questions about how to improve your dispensing process, don’t hesitate to email us at [email protected].