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.

General


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.

Technical Specifications


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

Operating Characteristics


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

Material Compatibility


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

Physical Characteristics


Compact footprint
Yes
Control panel type
Integrated
Discharge method
Automatic
Machine footprint
Minimal

Custom Options


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