Vial Loading & Unloading System
A good loading & unloading upgrade solution will increase the compliance with laws and regulations while increasing the efficiency simultaneously. It's strongly suggested to do a risk assessment before upgrade to identify the risk points and upgrade all unacceptable risk point accordingly. All these will ensure that the urgent target can be fulfilled at reasonable cost.
What we can do?
We have studied the requirements of GMP, EUGMP and FDA in details. We know every detail regarding to sterile operation and transfer.
We could assist to identify the risk point of current operation in the progress of confirming upgrade solutions. We are also capable of upgrading based on maximum use of old equipment to suit new operation module.
We can do upgrade both for vial and tray products. We could rebuild the freeze dryer, such as door direction, angle, shelves distance and quantities.
When the semi-automatic reached a more automatic level, the signal transmission, the coordination and interlock between equipments become quite important. Our team is capable of upgrading the control system of each equipment to avoid the risk to the maximum.
We can assist to validate or validate indepedently after upgrade. We will assist clients to understand the overall performance of all equipments.
Why us?
With more than 10 years' experience in sterile transfer and freeze drying, we know the current status and future development very well which ensure us to judge the economy and necessity of the solution. As a result, the target can be achieved at lower cost with maximum efficiency.
Solutions
Taking the construction convenience after upgade into consideration is the biggest difference between buidling a new one and upgade an old one. As a result, the upgrade solution will focus on design and application in modularity. Later combine all function modules as building blocks in order to realize the requirements of operations on construction stage.
The loading & unloading can divide into following modules based on function.
1. Frame in Column Module:
This module starts to collect vials from filling machine, sort them out in column and slip over outer frame. The methods include manual, semi-automatic and automatic.
2. Transfer and Transport Module:
This module starts to collect vials from filling machine, sort them out in column and slip over outer frame. The methods include manual, semi-automatic and automatic.
3. Loose Frame Module:
This module starts to collect vials from filling machine, sort them out in column and slip over outer frame. The methods include manual, semi-automatic and automatic.
Mobile Vehicle Transfer
Mobile vehicle is applicated to irregular workshop, freeze dryer layers without equal height and freeze dryers which need big entrance or manual rotating small entrance for material loading & unloading.
Track Transfer
Track transfer is applicated to upgrade regular workshop, freeze dryers layers with equal height and automatic entrance for material loading & unloading.
Mobile Vehicle and Track Mixed
The mixed method is applicated to upgrade regular workshop and freeze dryer with big entrance in aseptic space.
Semi-automatic Transfer Auxiliary Parts-ORABS Protection
Aseptic protection is the most important auxiliary system out of transfer system during transfer process. Normally ORABS is applicated to guarantee aseptic environment. Operations in gloves are applied for necessary manual operation.
ORABS separates into active type, passive type and equipped with or without laminar flow blowing.
Semi-automatic Transfer Auxiliary Parts-Frame Treatment
Aseptic frame will be used during transfer process, so the cleaning, sterization and aseptic transfer are auxiliary steps that cannot be ingnored.
Normally frames are cleaned manually, sterized with moist heat sterilization chamber and tranferred to point of use. Then frames will be transferred to frame mechanism in maunal or automatic way.
Automatic Loading & Unloading System
Automatic Loading & Unloading Advantage
- Automatic, isolated and continuous aseptic transfer system
- Reducing the risk of randomicity during transfer.
- Efficiency increased and production composite cost decreased
RBR
Each freeze dryer is equipped with one set of loading & unloading alone. Cillin bottles will be transfered to the door of freeze dryer by mesh belt and push to the shelves of freeze dryer row by row after being arrayed.
The main units include convey mesh belt, array system, loading propulsion mechanism, bridge mechanism connecting shelves and unloading propulsion mechanism.
AGV
One set of loading & unloading system can cooperate with several freeze dryers. The cillin bottles will be transfered to customized platform where al the bottles will be arrayed to the size of one shelf. Then the AVG vehicle will transfer the bottles to the shelf of freeze dryer.
The main units include convey mesh belt, bottle arraying platform, AGV vehicle and unloading platform.
MLUS
Loading & unloading are equipped in two aseptic room respectively. It can increase the efficiency significantly by using RBR or AGV to transfer different raw materials simultaneously.
This type is mainly used in workshop with a big quanity of freeze dryers.
Suitable for product on a large scale in a short period.
