Automatic loading and unloading system for pharma freeze dryers
Enhance the efficiency and safety of your freeze-drying process by minimizing contamination risks and reducing processing times with advanced loading and unloading solutions tailored for pharmaceutical applications.
Automates Vial Loading and Unloading for Lyophilizers
The ALUS® Automatic Loading and Unloading System by GEA enhances your lyophilization operations by ensuring seamless integration into pharmaceutical and biotech production lines. Designed to minimize contamination risks, it supports both toxic and non-toxic lyophilized products, including vaccines and oncology drugs, offering throughput speeds of up to 700 vials per minute. The system provides flexible automation options, from manual to fully automatic, ensuring compatibility with diverse vial formats and operational conditions. Its modular design allows for integration with existing production lines, and its ATEX-compliant versions handle potent substances safely. The system is built with durable, GMP-compliant materials, ensuring ease of maintenance and adherence to industry standards. Configurations can be tailored to meet specific containment and processing needs, supported by GEA’s extensive engineering expertise.
Benefits
- Enhances production efficiency with high-speed vial processing up to 700 vials per minute.
- Minimizes contamination risk through automated, contact-free loading and unloading.
- Reduces operational costs with energy-efficient designs and minimal maintenance requirements.
- Provides flexible integration options for diverse production layouts and vial formats.
- Ensures compliance with stringent industry standards, including ATEX and GMP certifications.
- Applications
- Toxic products,Lyophilized products,Vials,Biopharmaceuticals,Powders,Freeze dried products,Non-toxic products,Pharmaceuticals
- End products
- Vaccines,Instantly soluble powder medications,Lyophilized cell therapies,Hormonal treatments,Cytotoxic agents,Antibody formulations,Antisera,Lyophilized injectable drugs,Enzyme formulations,Freeze-dried herbal extracts,Oncology drugs,Protein therapies,Plant-based biopharmaceuticals,High-potency active pharmaceutical ingredients (hpapis),Biotech-derived active ingredients,Antibiotics in vials,Diagnostic reagents,Probiotics in powder form
- Steps before
- Vial preparation,Filling,Stoppering,Transfer to freeze dryer shelves
- Steps after
- Unloading,Vial inspection,Packing,Labeling
- Input ingredients
- vials,pharmaceutical vials,prepared vials,vials with product,lyophilization materials
- Output ingredients
- freeze dried vials,processed vials,finished pharmaceutical products,lyophilized products,vials post-process
- Market info
- GEA is known for its expertise in engineering innovative and sustainable equipment and solutions, focusing on sectors such as food, beverages, pharmaceuticals, and energy, with a reputation for quality, efficiency, and advanced technological applications in industrial processing.
- Loading speed
- Up to 500 vials per minute
- Unloading speed
- Up to 700 vials per minute
- Vial diameter – height ratio
- <3
- Containment options
- RABS,cRABS,isolator
- Flexibility
- Multipurpose lines
- Transfer cart system
- Automatic guided vehicles (AGV)
- Third-party integration
- Filler and capper options
- System configuration
- Pass through design
- Compliance
- ATEX-compliant versions
- Footprint
- Compact and adaptable design
- Software
- Integrated software for easy use
- Parallel operation
- Parallel loading and unloading
- Material used
- Stainless steel and FDA-compliant material
- Bellow Protection
- Yes,in Backpusher and Bellowpusher
- Moisture measurement
- LYOSENSE® Online Moisture Measurement
- Vial format handling
- Single and double row loading
- LAF protection
- Yes,for certain containment zones
- Power Supply
- Uninterruptable for all movements
- Automation level
- Manual / Semi-automatic / Fully automatic
- Batch vs. continuous operation
- Batch / Inline Continuous
- CIP/SIP
- CIP 121°C / SIP 135°C
- Changeover time
- Rapid product changeovers
- LAF protection
- Yes
- Energy efficiency
- Cost-effective containment
- Biological compatibility
- FDA-compliant materials
- Cleanability
- H2O2-resistant covering
- Corrosive resistance (e.g. acids)
- Stainless steel
- Density/particle size
- 0.5–2.5 g/cm³ / 50–1000 µm
- Abrasion resistance
- Stainless steel
- Compact footprint
- Yes
- Control panel type
- Integrated
- Discharge method
- Automatic
- Machine footprint
- Minimal
- Control panel type
- PLC with integrated software
- Compact footprint
- Yes
- Discharge method
- Push-Pull System / Transfer Cart System
- Customization for Containment
- oRABS / cRABS / Isolator Compatible
- Loading/Unloading configuration
- Single or dual-side
- ATEX compliance
- Available upon request
- Layout Options
- Parallel loading/unloading,T-shape configuration
- Handling Systems
- Frames / Trays / Vials / Carpules
- Product Flow Options
- Multipurpose lines for a broad range of products and formats
- Isolator integration
- Available
- Automation
- Manual / Semi-automatic / Fully automatic
- Additional options
- LYODATA vial traceability / LYOSENSE moisture measurement