Sterile lyophilized filling line

Ensure sterility and precision in filling pharmaceuticals with advanced isolator lines designed for handling sensitive biopharmaceuticals and ophthalmic solutions.

Fills and Seals Vials and Syringes Aseptically

The Aseptic Vial and Syringe Filling Isolator Lines from Telstar offer an integrated solution for pharmaceutical manufacturers, ensuring sterile filling and sealing of vials and syringes. These lines feature a multi-chamber isolator system that maintains sterility with HEPA-filtered laminar airflow and are designed for both batch and continuous operations, minimizing contamination risks. Ideal for producing lyophilized monoclonal antibodies, vaccines, and sterile solutions, these isolators handle both liquid and solid forms with high precision. The system supports integration with upstream and downstream processes, such as lyophilization and packaging, and is controlled via a PLC for seamless operation. Constructed in stainless steel to withstand rigorous cleanroom conditions, the isolator lines comply with GMP standards, offering automated cleaning processes for efficient maintenance. Custom engineering support is available to tailor the equipment to specific production needs.

Benefits

  • Ensures product sterility, reducing contamination risk during high-speed filling operations.
  • Optimizes production efficiency with integrated filling and sealing capabilities.
  • Lowers maintenance costs with automated cleaning and easy sterilization.
  • Enhances production flexibility by supporting both batch and continuous modes.
  • Complies with GMP standards, ensuring regulatory adherence for pharmaceutical applications.

General


Applications
Pharmaceuticals,Active pharmaceutical ingredients (api),Pharmaceutical syringes,Biopharmaceuticals,Hygroscopic products,Pharmaceutical vials,Ophthalmic products
End products
Lyophilized vaccines,Api powder forms,Ophthalmic sterile solutions,Sterile vials of medication,Lyophilized monoclonal antibodies,Pre-filled syringes of biologics,Lyophilized enzyme preparations
Steps before
API Weighing,Charging API,Inline Milling
Steps after
Unloading of Hygroscopic Product,Lyophilization Cycle,Sterile Packaging,Aseptic Ophthalmic Filling
Input ingredients
aseptic vials,syringes,API (Active Pharmaceutical Ingredient)
Output ingredients
filled aseptic vials,filled syringes
Market info
Telstar is known for specializing in the design, engineering, and manufacturing of advanced vacuum and aerospace solutions, gaining a strong reputation for their innovative and customized equipment in pharmaceutical, medical, and scientific research sectors.

Technical Specifications


Aseptic Conditions
Isolator-based
Filling Line Type
Aseptic Vial and Syringe
Number of Chambers (Vials)
Three
Number of Chambers (Syringes)
Single
Filling Machine Integration
Integrated to bedplate
Transfer Tunnel
Single chamber with conveyor integration
Automation
PLC-controlled
Pharmaceutical Application
Sterile Lyophilised Filling
Year of Installation
2017 and 2020
Location
Korea

Operating Characteristics


Automation level
Manual / PLC / SCADA
Batch vs. continuous operation
Batch / Inline Continuous
CIP/SIP
CIP 121°C / SIP 135°C
Cleaning method
CIP / Manual
Energy efficiency
0.5–2 kWh/kg moisture

Product type Characteristics


Container size and shape
Vial/Syringe

Physical Characteristics


Tunnel Shape
Single chamber
System Integration
Integrated to the Filling Machine bedplate
Transfer Method
Single chamber transfer tunnel,integrated to the transfer conveyor

Custom Options


Control panel type
Touchscreen HMI
Integration possibilities
Close coupled to the Filling machine Isolator
Chamber configuration
Single,Three-chamber options
Filling Line Type
Aseptic Vial Filling (PVL),Aseptic Syringe Filling (DCS)
Transfer tunnel
Single chamber integrated to transfer conveyor