Integrated vial filling machine for aseptic and toxic processing of pharmaceuticals

The integra is specifically designed to minimize product loss in all phases. When starting up, the first vial per filling point is already filled with the specified volume; when running empty, the pumps can be controlled individually so that only the last filled vial per filling point could show an underfill.

To further minimize product rejects, the integra can be designed with a stopper repositioning function, allowing to the loss of a stopper to be compensated by repositioning it.

Our stopper transport bowl can convey all common plugs, the sorting only takes place in the integrated sorting device, which can be aseptically removed without any problems. This reduces the number of stopper-dependent format parts and, as a result, enables the shortest set-up times for changeovers. The sorting and feeding unit is easy to clean and easy to see.

The walking beam can be adjusted using a servo motor and can be set up for different processing objects. This way the number of format parts that would otherwise have to be changed is reduced by around 50% compared to conventional production lines.

The low machine depth of the integra allows one-sided air extraction in the filling and discharge area. The filter cartridges are attached to the back of the isolator.

For toxic product processing, the entire line is equipped without vacuum. A mechanical stopper setting function, a mechanical rejects ejection and the avoidance of bellows seals allow the optimal processing of toxic products and the necessary cleaning.

The slim machine design of the entire system is an essential element of the integra. The low depth of intervention makes it possible to operate the entire system from one side, during setup and during operation.

The low machine depth of 650 mm also makes it possible for all line areas to be easily reached during cleaning. The line can also be set up at an angle allowing the cleaning medium to drain directly into a drain located on the back of the isolator directly in front of the HEPA filter cartridges.

With the integra, the sterile barrier is integrated into the filling machine; this is is where the proven SKANFOG decontamination technology comes in to play. In combination with the compact design of the entire system, it allows to achieve the shortest cycle times.

With integra, the HEPA filters are installed in filter cartridges, the so-called FIPAs. The cartridges can be unlocked manually or fully automatically via the panel control. This is particularly important for toxic processing: Due to the design, there is never a risk of contamination for operating personnel or the environment.