The new nest and tub system SCHOTT adaptiQ™ can also be used together with existing nest filling systems and enables pharmaceutical companies to freeze dry, weigh or close filled vials inside the nest. Photo: SCHOTT/ A: Sell
Higher Efficiency for Pharmaceutical Companies
Innovative ready-to-use pharmaceutical vials enable pharmaceutical companies to make more flexible use of their production lines and lower the total costs of ownership.
Pharmaceutical vials are usually washed and sterilized shortly before they are filled with medications. This calls for pharmaceutical companies to use their own washing machines, clean rooms and sterilization tunnels to perform these tasks. Companies are now increasingly looking to outsource these process steps. One way to increase the efficiency of filling lines is to use ready-to-use packaging materials that are delivered pre-washed and sterilized by the packaging manufacturer. This type of packaging has since become the industry standard for prefillable syringes. And for good reason. Packaging manufacturers like SCHOTT supply sterile syringes completely packaged in a nest and tub configuration. They are ready to be filled. Besides, there is no need for the pharmaceutical company to wash and sterilize them. Yet another advantage arises during the filling process: securely fixed in the nest, the containers cannot come into contact with each other, tip over or break.
SCHOTT adaptiQ™ consists of a tub and a nest, in which up to 100 sterile and prefillable vials can be securely fixed. Each container is held securely in place at the neck by a snap-in hook (picture bottom right). This prevents them from coming into contact and thus breaking or being scratched during the manufacturing process. Photo: SCHOTT
Due to the increasingly smaller batches in the pharmaceutical industry, flexibility and efficiency with respect to filling the various packaging products such as syringes or vials, there are new demands from the pharmaceutical industry. ”If pharmaceutical companies can fill several types of packaging such as syringes, vials and cartridges flexibly without long set-up times on their existing filling lines, this will make them more efficient and lower their costs,” Deutschle says.
SCHOTT worked closely with filling line manufacturers such as Bausch & Stroebel, Bosch, GEA and Optima for two years in order to develop an appropriate filling system for vials. The result is SCHOTT adaptiQ™, the first ready-to-use system in which the vials can be subjected to all of the process steps and remain in the nest. It can be used with existing nest filling systems and allows pharmaceutical companies to freeze dry, weigh or close filled vials inside the nest.
”Pharmaceutical companies can lower their operating costs by using adaptiQ,” Deutschle adds. Savings result from outsourcing to SCHOTT process steps such as depyrogenization, washing and sterilization, and also from no longer having to spend money on washing machines, sterilization tunnels and other equipment. SCHOTT plans to launch the adaptiQ™ ready-to-use system in the third quarter of 2014 in the most customary iso formats 2R and 4R (2 and 4 milliliters) and then gradually add other iso formats from 2 to 30 milliliters. <
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