End-to-end solutions for biopharma bottles: increase efficiency and reduce risk

The concept of end-to-end solutions is transforming industries with a focus on seamless and efficient processes. For biopharmaceuticals this includes filling, freezing/thawing and transporting sensitive drug substances by using a single platform. Considering single-use bottles, only isolated solutions for working within those processes were available. This is why biopharmaceutical bottles were not filled using an automated and aseptically closed system. Single Use Support has addressed this problem and accomplished the last missing link of end-to-end solutions for biopharma bottles.

What is special about it? The end-to-end process applies independently from pharma bottle manufacturers. Furthermore, it is modular and can be topped off with services such as qualifications, after-sales service and biopharma know-how. 

Challenges of manual bottle handling in biopharma

Manual bottle handling in biomanufacturing leads to many risks. It is slow, prone to human error, and has a high risk of contamination. These factors can jeopardize product quality and safety, making it challenging to scale up production. To maintain product integrity and increase efficiency, closed and automated systems are crucial. For optimal results and to minimize risks throughout the entire workflow, a comprehensive end-to-end solution is necessary.

Why manual bottle filling puts biomanufacturers at risk

The last missing link of end-to-end bottle solutions

To cover the entire process from A to Z, the biopharma industry has so far been confronted with bottles from various suppliers. However, if the process involves different providers the risk of incompatibility, product loss or damage caused by human error increases. Single Use Support meets these challenges and revolutionizes not only end-to-end solutions for single-use bags but also for single-use bottles.

So far, Single Use Support provides the following end-to-end solutions for bottles:

• Bottle.RoSS: Protect your single-use bottle of all sizes
• Bottle.FILL Bottle: Closed bottle filler for drug substances
• RoSS.pFTU: Controlled freezing/thawing of single-use bottles
• RoSS.BLST: Blast freezer for pharma bottles
• RoSS.ULTF: Temperature-controlled storage to maintain cold chain
• RoSS.SHIP: Protect your bottles for transportation at sub-zero temperature

Bottle assemblies for aseptic filling

Previous products used for filling, freezing/thawing and transporting single-use containers have been complemented by internally produced single-use bottle assemblies – finally completing the end-to-end process in this area.

The major advantage of end-to-end solutions for bottles is that all process steps are carried out by only using a single platform. Companies in the biopharmaceutical industry are thus able to work flexibly and efficiently. Moreover, they benefit from independence from manufacturer, scale, size, and single-use components.

In addition, Single Use Support filling, freezing and storage platforms can be used not only for single-use bottles, but also for bags as well. By providing hybrid end-to-end process solutions for both primary packagings, Single Use Support achieved another milestone in bioprocessing efficiency. This makes switching from single-use containers to single-use bags or working simultaneously with both much easier. Thus, a positive effect on storage space and costs can be achieved.

Optimizing your workflow with Single Use Support's integrated platform 

Single Use Support offers an elaborate platform for single-use containers and bags that covers the entire process from filling and filtration to freezing/thawing and shipping. Unlike stand-alone silo platforms, this approach addresses specific manufacturer and laboratory requirements. It is high time to let go of said silo mentality that still dominantes many areas and industries. It is time to increase rationalization processes and to eliminate the risk of product loss.

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