Integrated vial filling system for aseptic and toxic pharmaceuticals

Minimize product loss and ensure high sterility in vial filling while handling aseptic and toxic products with precision and speed.

Fills, Decontaminates, and Seals Vials Aseptically

The integra Integrated Vial Filling and Isolator Technology System from groninger combines precise vial filling with the latest isolator technology for aseptic and toxic pharmaceutical applications. This system is engineered to enhance safety and efficiency, featuring SKANFOG decontamination for maintaining sterility. Designed for biopharmaceutical and biotech industries, it processes up to 400 vials per minute across a range of 2R to 100H vials, ideal for products like vaccines and monoclonal antibodies. The system’s automation and integration capabilities include servo motor adjustments, rapid changeovers, and stopper repositioning to minimize downtime and product loss. The integra’s compact design is compliant with GMP and allows full monitoring and control through advanced PLC systems, ensuring the highest standards in safety and operational efficiency. Available with options for stainless steel construction, the system also incorporates user-friendly elements like easy access for cleaning and maintenance through its ergonomic design. With comprehensive engineering support, groninger ensures that the integra adapts seamlessly into existing production lines for pharmaceutical manufacturers and CMOs.

Benefits

  • Minimizes product loss with precise filling and stopper repositioning functions.
  • Shortens changeover times by 50% with efficient format part design.
  • Enhances operational safety with fully automated HEPA filter changes.
  • Increases productivity by processing up to 400 vials per minute.
  • Maintains sterility and compliance with integrated SKANFOG decontamination technology.

General


Applications
Toxic products,Aseptic products,Biotech products,Biopharmaceuticals,Pharmaceuticals
End products
Monoclonal antibody vials,Cytotoxic drug vials,Insulin vials,Protein therapeutics vials,Antiviral drug vials,Cancer treatment vials,Sterile oncology medication vials,Biologic drug vials,Vaccine vials
Steps before
Washing,Sterile preparation
Steps after
Stopper setting,Crimping,External washing,Packing
Input ingredients
vials,aseptic products,toxic products,2R-100H Vials,filling volume 1-100ml
Output ingredients
filled vials,up to 400 vials per minute
Market info
Groninger is known for its expertise in manufacturing high-quality filling and packaging machinery for the pharmaceutical, cosmetics, and consumer healthcare industries, with a strong reputation for innovation, precision engineering, and customer-focused solutions.

Technical Specifications


Output
up to 400 vials per minute
Processing range
2R-100H Vials
Filling volume
1-100 ml per vial
In-Process-Control (IPC)
100%
Residual oxygen content
Minimum of =1%
Vacuum-free line
For toxic products
Cycle time
1 hour < 1 ppm with SKANFOG® technology
NANOX® catalyst technology
0.1 ppm
HEPA filter system
Automated and safe change (“FIPA”)
Filling method
groninger smartfill technology
Machine design depth
650 mm

Operating Characteristics


Automation level
PLC/SCADA
Batch vs. continuous operation
Batch / Inline Continuous
CIP/SIP
CIP 121°C / SIP 135°C
Changeover time
Short
Cleaning method
CIP / Manual
Energy efficiency
Minimized product loss,waste
Process monitoring
100% In-Process-Control (IPC)
User-friendliness
Single-side operation
SKANFOG technology
Fast H2O2 cycle

Material Compatibility


Density/particle size
0.5–2.5 g/cm³ / 50–1000 µm

Product type Characteristics


Container size and shape
2R-100H Vials
Filling volume
1-100 ml per vial
Product compatibility
Bulk vial filling
Filling method
Volumetric / Gravity
Stopper system
Repositioning function
Decontamination technology
SKANFOG
Line configuration
Integrated Vial Filling Machine

Physical Characteristics


Machine footprint
Compact design
Control panel type
Fully automated panel control
Compact footprint
Single-side operation and setup
Machine depth
650 mm
Discharge method
Filter cartridge system with HEPA filters

Custom Options


Control panel type
Fully automated panel control
Filter system
HEPA filters with automated change
Integration possibilities
Interfaces between groninger and SKAN lines
Machine design
Compact design for easy access
Mechanical stopper setting function
Yes
Servo motor configuration
Adjustable walking beam
Smartfill technology
Minimum product loss via groninger smartfill
SKANFOG decontamination technology
Integrated with shortest cycle times
Stopper transport bowl
Integrated sorting device