Aseptic filling machines for pharmaceutical liquids

micheal-eder

Michael Eder

January 16, 2024

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Aseptic filling machines stand as the cornerstone in the filling of drug substance, ensuring the impeccable handling and packaging of delicate drug substances. These machines aren't just assembly line fixtures; they're the heartbeat of pharmaceutical production, bound to comply with high standards in terms of accuracy and sterility in aseptic filling.

In this article, we will talk about general and more professionalized aspects of aseptic filling machines. We will highlight their key elements, functionality, and critical role in maintaining the purity of pharmaceuticals, and are also going to introduce dedicated aseptic filling machines by Single Use Support.

What is an aseptic filling machine?

An aseptic filling machine is a vital component in pharmaceutical production, as it ensures the purity and sterility of drug products. Functioning within a strictly controlled, sterile environment, it plays a pivotal role in aseptic processing, safeguarding against contamination.

These machines precisely measure and fill drug substances, such as vaccines or medications, into containers like vials, syringes, or single-use bioprocess containers. By upholding stringent standards of quality and safety in liquid handling, aseptic filling machines meet the exacting demands of the pharmaceutical industry, ensuring that every dose delivered to patients is free from contaminants.

Aseptic filling machines by Single Use Support

RoSS.FILL - single use filling system for drug substances

RoSS.FILL | Fill-Filtration

RoSS.FILL is a fully automated single-use bag filling system. This allows maximum flexibility and scalability of both the filling and draining process. It is possible to fill unlimited volumes per batch with a speed of up to 300 liters per hour. The entire filling process is fully disposable, thus warranting an absolutely sterile fill & drain process. For further productivity improvements check out our pinch valve innovation.

Automated aliquoting system: From small volume aliquoting to bulk filling with RoSS.FILL

Steps and components of aseptic filling

Before the filling process, homogenization may take place, where the mixture undergoes thorough mixing or kneading to achieve uniform consistency, crucial in ensuring the quality of certain products.

In the following, aseptic filling and processing of biologics involves several key stages to maintain purity and quality of the processed goods. At the beginning of the filling process, the pharmaceutical product undergoes stringent filtration to eliminate any contaminants or impurities. Following this, the filling stage occurs, where the sterile product is precisely dispensed into containers, ensuring accurate dosing and preventing any microbial contamination.

The successful execution of aseptic filling relies on an array of vital systems and components. These include specialized equipment such as aseptic filling machines, which are designed to precisely dose and fill containers with drug products, maintaining a sterile environment throughout. The aseptic filler machines may consist of dosing units, high-speed capping mechanisms, stoppers, peristaltic pumps, and several other components, often tailored to the respective manufacturer’s needs.

Filtration and aseptic filling

Aseptic filling procedures maintain the sterile environment, crucial for preserving pharmaceutical integrity during the filling process. However, filtration plays an equally important role in pharmaceutical production, ensuring the removal of impurities and microorganisms from drug substances.

RoSS.FILL: Elevating aseptic filling standards

Single Use Support’s scalable RoSS.FILL platform redefines the aseptic filling process. Combining cutting-edge filtration mechanisms with advanced aseptic filling capabilities, this platform maintains the highest standards of sterility. With the option to integrate advanced filtration solutions, it can remove impurities before flawlessly transferring the purified substance into sterile containers with high precision, ensuring pharmaceutical integrity.

Homogenization is essential for maintaining consistent characteristics and quality of drug substances from aliquot-to-aliquot. It involves the gentle kneading and controlled cooling of single-use bags to guarantee a uniform mixture – a fundamental requirement for pharmaceutical substances like cell-based products.

RoSS.FILL - single use filling system for drug substances

RoSS.FILL | Fill-Filtration

RoSS.FILL is a fully automated single-use bag filling system. This allows maximum flexibility and scalability of both the filling and draining process. It is possible to fill unlimited volumes per batch with a speed of up to 300 liters per hour. The entire filling process is fully disposable, thus warranting an absolutely sterile fill & drain process. For further productivity improvements check out our pinch valve innovation.

Homogenization of drug substance

Homogenization is essential for maintaining consistent characteristics and quality of drug substances from aliquot-to-aliquot. It involves the gentle kneading and controlled cooling of single-use bags to guarantee a uniform mixture – a fundamental requirement for pharmaceutical substances like cell-based products.

RoSS.PADL: Standardizing homogenization processes

RoSS.PADL, designed by Single Use Support, focuses on controlled kneading processes in a temperature-controlled environment. This platform ensures uniformity in substance mixtures by deploying multiple cooling and kneading mechanisms. Its advanced automation minimizes human intervention, optimizing efficiency in the critical homogenization process essential for pharmaceutical substance preparation.

The adaptability of aseptic filling isn't solely about handling different volumes; it's vital for biopharma companies. Embracing scalability allows seamless adjustments between small-scale and large-volume production, ensuring flexibility in the production process.

Whether managing small batches or expanding to larger volumes, automation plays a pivotal role in enhancing efficiency of biopharmaceutical fluid management systems. Nevertheless, this leads to faster drug delivery and lowered costs, thereby increasing accessibility of potentially life-changing if not life-saving drugs.

Be it small-scale or large-scale applications – the standards in biopharmaceutical manufacturing concerning sterility and safety remain untouched. What, of course, does change, are the processed volume sizes, which requires systems that are capable of dealing with either small or bulk units of drug substances. A scalable platform, however, supports biopharma companies in making the transition between small and large-scale applications ever so smooth.

RoSS.PADL_Rendering_2

RoSS.PADL | Homogenizing Solution

RoSS.PADL is a scalable massaging platform for achieving a uniform mixture in
single-use bags. With integrated cooling and heating, it maintains optimal temperatures
consistently.

Scalability is key

The adaptability of aseptic filling isn't solely about handling different volumes; it's vital for biopharma companies. Embracing scalability allows seamless adjustments between small-scale and large-volume production, ensuring flexibility in the production process.

Whether managing small batches or expanding to larger volumes, automation plays a pivotal role in enhancing efficiency of biopharmaceutical fluid management systems. Nevertheless, this leads to faster drug delivery and lowered costs, thereby increasing accessibility of potentially life-changing if not life-saving drugs.

Be it small-scale or large-scale applications – the standards in biopharmaceutical manufacturing concerning sterility and safety remain untouched. What, of course, does change, are the processed volume sizes, which requires systems that are capable of dealing with either small or bulk units of drug substances. A scalable platform, however, supports biopharma companies in making the transition between small and large-scale applications ever so smooth.

Aseptic filling solutions for small-scale applications

Small-scale applications in biopharma demand precision and flexibility. These applications, often involving research, pilot studies, or initial production runs, require solutions that ensure compliance with stringent regulations like cGMP, minimize downtime, and offer versatile inline operations.

This, however, is also true for the wide field of targeted therapies like recombinant antibodies (rAbs) – pharmaceuticals that have been re-shaping the way many diseases are treated, catering to specific patient’s unique requirements. Nevertheless, temporary production lines as well as the limited shelf life of biologics make it necessary for pharma companies to optimize every production step in order to create high-quality pharmaceuticals while avoiding exuberant costs.

Single Use Support provides cutting-edge solutions like RoSS.FILL Lab Scale and RoSS.FILL CGT, ideal for these settings. The RoSS.FILL Lab Scale caters to precise volumes, maintaining quality in smaller batches, while the RoSS.FILL CGT enables efficient filling specifically for cell and gene therapy applications, ensuring validation and inline adaptability, essential for small-scale processes.

eBook: Advancing ATMP Fluid Management

Simplifying complex process logistics in fluid and cold chain management for cell & gene therapies in small volumes

Aseptic filling systems for large volumes

In biopharma, aseptic filling of large volumes of drug substance demand robust and efficient solutions to handle considerable quantities. These applications, such as bulk filtration, commercial bulk filling, or large-scale productions, require cutting-edge systems.

Single Use Support offers tailored process solutions designed to cater to these specific needs. From accommodating up to 400L per batch with RoSS.FILL Bag to enabling filling of up to 1000L with RoSS.FILL Base, and streamlining aseptic filling for up to 20 bottles concurrently using RoSS.FILL Bottle, these solutions ensure precision and compliance for large-volume applications.

Integrated with automated features, they ensure efficiency, scalability, and adherence to rigorous industry standards.

693-RoSS.FILL Bag

Additional single-use aseptic filling equipment

Single Use Support provides a range of specialized equipment designed to maintain aseptic conditions and enhance the efficiency of liquid filling and beyond. These solutions offer versatility, reliability, and compliance with regulatory standards during automatic filling of drug substances.

RoSS.PADL: Homogenization and cooling

As already described, RoSS.PADL ensures a uniform mixture within single-use bags while gently cooling them. Its automated mechanisms allow for scalable operations with precise temperature control, ideal for various drug substances and cell culture samples.

IRIS single-use bioprocess containers

The IRIS single-use bioprocess containers are qualified for storing, shipping, and freezing various substances within an extensive temperature range. They provide secure primary packaging for cell culture media and drug substances, reducing product loss during freezing, storage, and transportation – available in different sizes.

RoSS® Shell: Bioprocess container protection

RoSS® Shell is a robust solution designed to safeguard single-use bags during transport, freeze, and thaw stages. Its protective casing and the innovative inner layer coated with 3D foam minimizes product loss, maintaining the integrity of stored biopharmaceuticals.

IRIS Single-use assemblies: Customized manifolds

The customized IRIS single-use assemblies offer sterile fluid flow management and expedite aseptic filling. Built with quality materials, tubing solutions for biopharmaceutical liquids and other assemblies are designed for seamless integration into biopharma processes, minimizing downtime and ensuring regulatory compliance.

IRIS SEAL: Aseptic disconnection

IRIS SEAL, with its metallic pinch-pipes, facilitates safe disconnection of single-use assemblies, enhancing process flexibility in managing sterile fluids. Its design withstands pressure and complies with stringent cleanroom and biopharmaceutical standards.

Collectively, these solutions contribute to reducing product loss, optimizing sterile handling, and ensuring efficient processes. From improved homogenization to enhanced disconnection and protection, each equipment addresses critical aspects of aseptic filling by the means of cutting-edge single-use technologies.

micheal-eder

Michael Eder

Senior Marketing Manager

Michael Eder, MA, is Senior Marketing Manager at Single Use Support. He is expert in pharma and health communication with his 8+ years experience in pharma. After completing his master's degree in International Healthcare Management at MCI The Entrepreneurial school in Innsbruck, he has gained experience in the pharmaceutical field. Michael creates articles about Freeze Thaw applications and Platform solutions from Single Use Support and is the author of current news with Single Use Support worldwide. 

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