[admin]

In modern pharmaceutical manufacturing, the efficiency, precision, and safety of aseptic filling and capping operations are critical to meeting regulatory standards and ensuring high-quality injectable products. Jiangsu Pharmasys Intelligent Equipment Co., Ltd. has developed advanced automatic rotary filling and capping machines specifically designed for aseptic pilot production and small-batch injectable lines. These machines are engineered to handle the unique challenges of small-scale production while maintaining high throughput, consistent quality, and enhanced operational safety.

High-Precision Rotary Filling and Capping for Pilot Production

For pilot-scale production, maintaining flexibility and precision is crucial. Pharmasys’ rotary capping machines for pilot lines offer multiple capping methods, including knife capping and claw locking, allowing pharmaceutical manufacturers to adapt to various vial specifications without compromising on aseptic integrity. The integration of a flexible manipulator vacuum capping system ensures that each vial is sealed reliably while reducing potential environmental, health, and safety (EHS) hazards associated with manual handling.

Equipped with a servo-driven mechanism, these machines provide high-precision control over capping pressure. This enables operators to fine-tune the capping force according to vial type and filling material, ensuring that even sensitive biological formulations remain stable and contamination-free throughout the process.

Automated Loading and Capping Workflow

Pharmasys’ automatic loading and capping features significantly reduce manual labor and increase operational efficiency. Vials can be automatically loaded into the system, capped with precision, and discharged for downstream processing. The no vial, no capping safety interlock prevents equipment damage and production errors, while tool-less quick change parts facilitate fast adjustments for different vial specifications, reducing downtime and production delays.

Furthermore, these machines can seamlessly connect with upstream and downstream equipment, offering full integration into pilot and small-batch production lines. This interoperability allows for scalable production without the need for extensive reconfiguration.

Multiple Sealing Methods and High Flexibility

Different production requirements call for specialized sealing methods. Pharmasys’ rotary capping machines support a variety of capping options, including single knife, claw type, and advanced vacuum sealing. The adoption of high-precision servo drives ensures consistent torque and pressure during the capping process, minimizing the risk of leaks and contamination. Operators benefit from easy adjustments for pressing force, enabling the safe handling of vials filled with highly sensitive injectables or viscous formulations.

The flexible manipulator technology also enables precise handling of vials in constrained environments, making it ideal for integration with isolators or contained environments such as orabs and crabs, which are often used in high-risk aseptic filling operations.

Performance and Throughput

Despite being optimized for small-batch and pilot production, Pharmasys’ automatic rotary filling and capping machines do not compromise on speed. The system can achieve speeds of up to 50 vials per minute (vpm), balancing high throughput with stringent aseptic standards. By automating repetitive tasks such as vial loading, capping, and discharge, the equipment enhances operational productivity while ensuring consistent product quality.

According to the 2024 International Society for Pharmaceutical Engineering (ISPE) report, automation in small-batch aseptic filling can reduce human contamination risk by up to 60% while improving throughput by 25-40%, highlighting the critical role of automated rotary systems in modern pilot production.

Reliability, Safety, and Compliance

Pharmasys emphasizes high sealing reliability and operational safety in its design philosophy. The equipment is engineered to comply with cGMP and ISO standards, ensuring that each vial is filled and capped under controlled, sterile conditions. Integrated EHS safety features, such as vacuum manipulator operation and interlocked capping mechanisms, protect operators from injury while minimizing environmental exposure risks.

The robust servo-driven system ensures consistent performance across production cycles, reducing maintenance frequency and enabling long-term reliability in aseptic pilot production lines.

Applications Across Pharmaceutical Sectors

Pharmasys’ automatic rotary filling and capping machines are widely applicable across several sectors, including:

• Biopharmaceuticals: Ideal for pilot-scale production of vaccines, monoclonal antibodies, and other biologics where aseptic conditions are paramount.

• Medical aesthetics: Provides precise filling and capping for small-batch production of injectables like hyaluronic acid formulations.

• Advanced formulations: Handles sensitive injectable drugs requiring high-precision filling and capping to maintain potency and stability.

Optimizing Pilot and Small-Batch Lines

By implementing Pharmasys’ rotary capping systems, manufacturers can optimize their pilot and small-batch lines for efficiency, safety, and regulatory compliance. The combination of automatic loading, flexible vacuum capping, multiple sealing methods, and high-speed operation ensures that pilot production remains scalable and adaptable to evolving pharmaceutical product portfolios.

FAQ

Q1: Can the Pharmasys rotary capping machine handle different vial sizes?
A1: Yes, the system supports quick changeovers with tool-less adjustment, allowing for multiple vial sizes without compromising speed or aseptic integrity.

Q2: Is the equipment suitable for integration with isolators?
A2: Absolutely. The flexible manipulator vacuum capping system allows seamless integration with isolators, orabs, and crabs, making it suitable for high-containment environments.

Q3: What is the maximum production speed?
A3: The machine can achieve speeds up to 50 vials per minute, balancing high throughput with precise, aseptic operation.

Q4: Does the machine reduce EHS risks compared to manual capping?
A4: Yes, the advanced manipulator vacuum technology and interlocked mechanisms significantly minimize potential EHS hazards associated with manual operations.

Q5: Which pharmaceutical sectors can benefit most from this machine?
A5: Biopharmaceuticals, medical aesthetics, and advanced formulation sectors can all benefit from the precision, speed, and reliability of Pharmasys’ rotary filling and capping solutions.

---

Pharmasys continues to innovate in aseptic equipment solutions for pilot and small-batch injectable production. By combining automation, flexibility, and high-precision engineering, the company enables pharmaceutical manufacturers worldwide to enhance operational efficiency, product quality, and regulatory compliance.

http://www.pharmasys-tech.com
​Jiangsu Pharmasys Intelligent Equipment Co., Ltd.

[Author]

Posts