Project details
In order to live up to this vision and meet the increasing demands in the field of in vitro fertilization, Vitrolife was looking for an efficient solution to automate its production processes. The goal was to convert the previously manual processing of liquid products into a nearly fully automated line. The focus was on the highest quality standards, a compact design, and maximum flexibility in processing different container shapes and materials.
To implement this ambitious project, Vitrolife relied on groninger's many years of experience and technological expertise in the field of pharmaceutical filling. Together, a tailor-made concept was developed that combines all customer requirements in a compact, high-performance solution.
The biggest challenge – limited space
The biggest challenge in the project was the structural conditions: the new lines had to be integrated into an existing building, which was limited by fixed spatial boundaries. In addition, a Class B clean room was to be newly constructed – with the aim of keeping running costs as low as possible despite the small area. An additional challenge was the constantly changing production requirements: small batch sizes, very short shelf lives, frequent format changes, and technically demanding closure variants required maximum flexibility in the plant technology. To meet these requirements, groninger developed a customized solution based on the flexcare10 platform: two virtually identical lines that are characterized by their compact design, high flexibility, and process reliability.
Technical highlights
The systems process both glass and plastic bottles in round and square shapes with a filling volume of 5 to 250 ml. The plastic bottles are pre-sterilized and fitted with a screw cap, which is removed before filling and then replaced afterwards. The glass bottles, on the other hand, are sterilized and fed into the line without caps. The corresponding screw caps are then screwed onto the filled bottles at a dedicated screwing station.
Technical highlights include the active-oRABS system, which offers maximum product safety and high user-friendliness, as well as the integrated environmental monitoring system, which was provided by the customer and fully integrated into the system. Another notable feature is the digital guidance system, which provides targeted support to operating personnel during frequent product and format changes, enabling fast and safe changeover processes.
The result
groninger impresses with its ability to solve customer-specific challenges with innovative technology and well-thought-out project implementation – even under demanding pharmaceutical and spatial conditions and short delivery times.
Thanks to this solution, Vitrolife will be able to largely automate its manual production, expand its production capacities in a targeted manner, and at the same time maintain the highest quality and safety standards. The close and cooperative partnership with groninger is exemplary of a holistic approach to solutions, in which technological expertise, adaptability, and a deep understanding of processes are seamlessly intertwined.
Feeding of round glass and plastic bottles
Feeding of suqare glass and plastic bottles
Poor performance for non-compliant objects
Proper disposal of objects and transfer to unclassified area (final packaging)
Screw on with previously unscrewed caps
Filling with PP + 100% IPK
Unscrewing the screw caps
