The Industry Standard in Capping for Parenteral Vials

The RW Westcapper is a fully automated, constant motion, rotary crimper equipped with a six, twelve or eighteen spindle head, a circular hardened rail section, and Allen-Bradley controls.

Seal Integrity

A stoppered vial is a prevalent parenteral drug container closure system. The system however should not be considered integral until the rubber stopper is crimped firmly in place with sufficient compression against the vial, assuring all potential leakage is cut off at the seal interface. It is well understood that seal quality is critically important to maintaining sterility and stability of the drug product.

Seal integrity is achieved by adequately compressing the elastomeric closure against the sealing surface of the vial and maintaining that compression with a crimped aluminum ferrule. The amount of elastomeric compression is determined by the force applied during the crimping process. The Westcapper controls the force being applied to the elastomeric closure during this process which in turn, reduces variability of stopper compression, producing more consistent seals.

The RW Westcapper

A number of design improvements have been made to the RW Westcapper. Of these the most significant is the placing of the vibratory cap bowl to the discharge side of the capper. This greatly reduces the chances of particulate contamination in vials as they are sealed. The overall height of the capper has also been reduced due to the head height adjustment no longer raising and lowering the hopper system as it has been moved off to the side. The Westcapper has also been updated to help you meet the European Annex 1 regulations of the Manufacture of Sterile Medicinal Products.

Annex One

Follow the link below to learn more about how the RW Westcapper can help you meet European Annex 1 regulations for the Manufacture of Sterile Medicinal Products.

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Watch a Video

Watch a video of the RW Westcapper configured with a vision system looking for raised and missing stoppers as well as a post capping inspection station looking for visual defects.

Watch Video

Maximum operation speed is 750 vpm, depending on cap size. Desired machine speed is entered onto the Total Controls Touchscreen. The capper will automatically ramp up to set speed when put in the RUN function. This enables standard operations procedures to be met consistently with each vial.

A standard capper includes rolling casters. Stationary stainless steel legs are also available. Standard vial flow is from left to right. Vial flow from right to left is an available option. Conveyor height can range from 35-1/4″ to 38″. Standard conveyor length is 98″ with other conveyor lengths available as options.

The entire capping area of the machine is enlclosed with an OSHA compliant safety shield. The capper will immediately shut down when the shield is opened.

When Space is Limited

The RW Westcapper is also available in a smaller footprint design making it ideal for applications where space is at a premium and Annex 1 requirements are not necessary.

Maximum operation speed is up to 750 vpm, depending on cap size and spindle count. The desired machine speed is entered onto the Total Controls Touchscreen. The capper will automatically ramp up to set speed when put in the RUN function. This enables standard operations procedures to be met consistently with each vial.

A standard capper includes rolling casters. Stationary stainless steel legs are also available. Standard vial flow is from left to right. Vial flow from right to left is an available option. Conveyor height can range from 35-1/4″ to 38″. Standard conveyor length is 98″ with other conveyor lengths available as options.

The entire capping area of the machine is enclosed with an OSHA compliant safety shield. The capper will immediately shut down when the shield is opened.

RW Westcapper Technologies

Oil Free Operation

Genesis has developed sealing heads and conveyor support assemblies (pods) that no longer require the use of oil for lubrication. Bronze spindle bushings in the sealing head have been replaced with self lubricating, FDA compliant, polymer bushings and the conveyor support assemblies have been modified to retain grease used during fabrication. By employing polymer spindle bushings, we have eliminated the need for oil in the machinery directly above the product. The potential for oil dripping on vials is eliminated. Additionally, the vial rest table bearings are now sealed.

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Applied Force Monitor

The Applied Force Monitor (AFM) was developed to work in conjunction with our line of Westcappers. The monitor can be applied to both spinning roller and sealing rail technology machines. On sealing rail machines it will monitor up to three locations during the sealing process, each location adjustable for force range high and low limits. This means that the quality level, or acceptance criteria, can be easily dialed in to match the appropriate requirements for a particular application and regulatory requirement.

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Raised Stopper Detection

The RW Westcapper platform is very flexible and can be fitted with a either a vision or laser based raised/missing stopper detection system. As the vials enter the capper they pass in front of the system which determines whether or not a stopper is missing or raised based on the criteria that has been set in the PLC/PC based controls. All vials failing this criteria are rejected and ejected out of the system by a starwheel before entering the sealing stage of the capping process.

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Marking and Verification

The Genesis Vial-Trak system allows the application of an identifying mark to a vial and the immediate confirmation that the mark is properly applied (is able to be read). In the event of a non-conforming mark, the vial will be ejected from the production line for further action. With the optional vision system located prior to the labeler, the system ensures full compliance with current regulations.

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RW Product Matrix

18 Spindles 12 Spindles 6 Spindles
Max Speed (vpm) 750 600 300
Sealing Technology Sealing Rail Sealing Rail Sealing Rail
Hopper System Gravity Fed Vibratory Gravity Fed Vibratory Gravity Fed Vibratory
Seal Size 13-32 mm 13-32 mm 13-32 mm
Seal Style All Standard Serum All Standard Serum All Standard Serum
Vial Diameter 12.7-38.1 mm 12.7-57.15 mm 12.7-82.55 mm
Vial Height 28.575-158.75 mm 28.575-158.75 mm 55.549-180.84 mm
Construction Stainless Steel Stainless Steel Stainless Steel
Control System PLC Touchscreen Interface PLC Touchscreen Interface PLC Touchscreen Interface
Vial Infeed Sensor Standard Standard Standard
Jam Control Sensor Standard Standard Standard