COLANAR Partners with Specialized Small-Batch CMO Berkshire Sterile Manufacturing for Pioneer Project in Fully Automated Aseptic Filling

Background

COLANAR provides flexible, innovative solutions and specializes in advanced liquid filling systems and automated handling systems for small-batch Pharma, Biotech, and Life Science Industries. With facilities in both Europe and North America, we service a global customer base. Our continued focus on customer needs and our ability to react swiftly and cost-efficiently, while remaining customer oriented, ensures a successful relationship with our customers.

In preliminary talks, BSM conveyed the following new project wishlist:

• Fill and finish multiple container types and sizes
• Process RTU and bulk vials
• Both peristaltic and piston pump options
• 100% automated

COLANAR’s Solution

COLANAR is excited for the opportunity to collaborate with BSM to create and install a fully automated filling line that is also flexible enough to fill many container types with a variety of different viscosity products. This FSO features advanced nitrogen purging for a residual oxygen  headspace of less than 1%. Additionally, Colanar obtained two top of the line, aseptic compatible Staubli robots.

Bernd Stroeter, President at COLANAR explains, “We created a concept using 6-axis cleanroom robots in combination with our proven filling equipment to fulfill their specific requirements. They purchased our robotic filling machine and then developed a line layout around this filling machine including a vial washing machine, a vial sterilizing tunnel, a robotic RTU tub sterilization and delidding system as well as automated lyophilization loading and unloading equipment and a vial capping machine.”

Adding automation to the system, particularly for a fully automated line, requires advanced programming and troubleshooting. It is a challenge that programmers here at COLANAR were excited to take on. The installation of vision systems allows robots to check their work during operation. COLANAR selected Cognex vision systems and installed a camera on each robot arm as well as one centered above the two robots. This integrated vision system verifies that the robots place the vials properly and that the no vial/no fill requirement is met. The designated unloading robot will automatically separate rejected vials into a designated reject station.  

The COLANAR FSO’s extreme flexibility and integrated full automation make this particular project one of the most innovative in Pharma today.