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Intelligent equipment for aseptic filling of ready-to-use containers in a nest

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Syringes, cartridges or vials : Filling and packaging pre-sterilized components in ready-to-use (RTU) containers requires specialized system technology. This is our core competence: From custom-fit syringe filling machines to complete turnkey solutions, including pharmaceutical isolators  for your application.

Container filled with vials
Rely on filling equipment that is as ready-to-use like your containers

Time and cost in pharmaceutical developments are increasing. To help you start production feeling more confident and, above all, faster, we have developed CSPE (Comprehensive Scientific Process Engineering) and other intelligent end-to-end processes. Our mission: Accelerate your time to market, as well as your operational process times.

We design system technology for your primary packaging and secondary processing, which are agile and precisely tailored to your needs, based on Optima’s technology platforms. Encompass all steps from filling and closing, including upstream and downstream processes: From nest removal to labeling, as well as the insertion of piston rods, assembly of safety devices, finger flanges and much more.

Process steps for handling your RTU containers in the nest
Process steps for handling your RTU containers in the nest
Machine for RTU containers in the nest
1. De-bagging
2. Remove Tyvek® film
3. Filling and closing
4. Monitoring
5. Isolator
6. Secondary processing
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Machine for RTU containers in the nest
1. De-bagging
Process step: Unpack the bag

Whether your RTU packaging materials arrive single or double bagged at the filling line, you can choose a manual, semi-automatic or fully automatic system from our portfolio. Bags are opened to remove the tubs. The tubs are pushed out of the bag, without being touched and then transferred to the sterile area.

Benefits:

●       Unpacking of the tubs either manually, semi-automatically or fully automatically

●       The tub is transported, to the next station, without being touched

Multiple options for transfer to sterile area (single or double bag, E-Beam)

2. Remove Tyvek® film
Process step: removing the Tyvek® film

A robot specifically designed for use in the cleanroom removes the intermediate layer of Tyvek® film.

Benefits:

  • Sterile room compatible robot system
  • Clear separation of cleanroom areas
  • Compact and pharmaceutical grade design
3. Filling and closing
Dosing system of a filling machine

Whether viscous or fluid: With the correct aseptic filling system, you can accurately fill any type of product – with either rotary piston pumps, peristaltic pumps or a time-pressure filling system. Solutions like single-use or CIP/SIP (cleaning-in-place/sterilization-in-place) for the filling path are available. Upon request, containers can be filled and closed under vacuum.

No matter how you envision your system, together we will develop the optimal solution for you. No matter what you select, the design is compact, easily accessible and easy to operate.

Benefits:

  • Filling and closing of nested prefilled syringes, vials and cartridges
  • Up to 60,000 pieces per hour
  • Filling systems and filling paths to accommodate the product
  • Application-friendly systems with integrated in-process control
4. Monitoring
Process step: control

Short acronym, big effect: The SIRM (Syringe Inspection and Reject Machine) is an exceptionally safe inspection system for syringes, a crucial component of our syringe filling equipment. It uses a robot and several cameras to remove defective syringes or cartridges from the tub. It also verifies the stopper height of the objects.

Benefits:

  • Automated inspection of syringes or cartridges
  • Discharge of individual objects
  • Maximum security
5. Isolator
Pharmaceutical machine view with isolator

Containment solutions including isolators complement our turnkey portfolio for filling RTU nested containers. Good to know: You can combine the isolators with any type of pharmaceutical equipment, as well as numerous process functions.

More on Optima Pharma Isolators

6. Secondary processing
process post-processing

Do you need to process filled and closed RTU containers? Choose from the comprehensive machine portfolio for secondary processing: Solutions for labeling, inserting and assembling piston rods, backstops and safety devices. Syringe transport systems, buffer systems, denesters and renesters complete the syringe secondary-processing portfolio.

Benefits:

  • Large portfolio for secondary processing
  • Compact systems for labeling and inserting piston rods
  • Appropriate backstop and safety device assembly machines
  • Syringes and buffer systems to meet your space requirements
  • Everything from one manufacturer: Saving time and reducing interfaces
Akshay Chikodi
Akshay Chikodi, Director Sales & Service, OPTIMA India packaging machines Pvt. Ltd.

A toolless change of size parts and labeled format parts provide a fast and safe retrofit.

Akshay Chikodi, Director Sales & Service, OPTIMA India packaging machines Pvt. Ltd.
OPTIMA pharma | Experts for aseptic filling
Do you have questions or would you like to discuss your specific requirements with Optima's experts?
OPTIMA pharma | Experts for aseptic filling
OPTIMA pharma
+49 791 9495 - 0 customer.info@optima-packaging.comWrite e-mail
OPTIMA pharma | Experts for aseptic filling
OPTIMA pharma | Experts for aseptic filling
OPTIMA pharma
Good to know Aseptic syringe, cartridge or vial filling: Applications from A to Z

Start-ups, contract manufacturers and big pharma from biotech to pharmaceutical industries worldwide choose Optima. Our team develops and designs systems for filling products in R&D, clinical trials, production of small quantities, as well as commercial production of any batch size. We find solutions through our expertise, ingenuity and a holistic understanding of your value chain. The result: A highly accessible, flexible and process-reliable production. For example, complex turnkey systems from Optima Pharma can handle vaccine filling, highly-potent products, heparin, hyaluronic acid, biotech and biosimilar products, generics and veterinary products.

Person being vaccinated
Vaccines

Time is often a critical factor in vaccine filling processes. Optima accelerates filling and packaging of sterile liquids with innovative systems.

People in a laboratory
High potency drugs

A complete overview is essential when filling and processing high-potency pharmaceuticals – which is why we create comprehensive processes for maximum safety.

Doctor drawing up syringe
Biotech and biosimilars

For challenging productions, we offer holistic process expertise for aseptic filling, including maximum product protection.

Woman is injected with hyaluronic acid in her face
Hyaluronic acid

For hyaluronic acid products, rely on air bubble-free filling and stopper insertion, as well as high precision filling, cleaning and product infeed.

Filling RTU containers The basics of flexibility

The use of ready-to-use containers is increasing – with an Optima Pharma filling system, you remain flexible. Because you can use it to fill a wide range of products with different requirements, including pre-sterilized syringes, vials or cartridges.

Fill RTU packaging
Filling RTU containers The basics of flexibility

The use of ready-to-use containers is increasing – with an Optima Pharma filling system, you remain flexible. Because you can use it to fill a wide range of products with different requirements, including pre-sterilized syringes, vials or cartridges.

Fill RTU packaging
Technology with added value Benefits of safe processes

Safety is everyone’s number one priority. With Optima, numerous in-production controls with sensors and camera systems monitor your processes and products. We also offer a wide range of inspection and control technologies for various processes. In each case, the objective is your top product quality.

Camera sensor
Technology with added value Benefits of safe processes

Safety is everyone’s number one priority. With Optima, numerous in-production controls with sensors and camera systems monitor your processes and products. We also offer a wide range of inspection and control technologies for various processes. In each case, the objective is your top product quality.

Camera sensor
Intelligent support Digital perspective

With Optima's digital solutions, you gain production transparency. In addition, you can identify optimization potential, increase system availability and receive quick support, if needed. Because of the IPAS (Intelligent Production Assistance Services), developed by Optima, you have direct access to assistance and a broad knowledge database at any time during the production process.

Optima employee maintains a pharmaceutical machine with the help of AR glasses
Intelligent support Digital perspective

With Optima's digital solutions, you gain production transparency. In addition, you can identify optimization potential, increase system availability and receive quick support, if needed. Because of the IPAS (Intelligent Production Assistance Services), developed by Optima, you have direct access to assistance and a broad knowledge database at any time during the production process.

Optima employee maintains a pharmaceutical machine with the help of AR glasses
The right system for every output of your ready-to-use packaging materials

If you are seeking a suitable system to fill different formats of sterile products in ready-to-use packaging like syringes, vials, or cartridges, Optima can help. We provide solutions for every application and every batch size – small or large, R&D, clinical trials or commercial production. For high speed performance, we offer filling systems with a capacity of up to 60,000 pieces per hour, for filling sizes of up to 50 ml.

Machine for RTU containers
From small and compact...
Machine for Ready-to-Use containers
… to a large and powerful performance
Success stories from the world of RTU containers – by and with OPTIMA pharma

Real examples are the best approach to show the benefits of Optima's well-designed solutions. Dive into our success stories and become inspired.
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OPTIMA pharma | Experts for aseptic filling
Do you have any questions about aseptic filling using MultiUse systems, or would you like to discuss your specific requirements?
OPTIMA pharma | Experts for aseptic filling
OPTIMA pharma
OPTIMA pharma | Experts for aseptic filling
OPTIMA pharma | Experts for aseptic filling
OPTIMA pharma
+49 791 9495 - 0 Write e-mail
Three Optima employees
Do you have questions or would you like to discuss your specific requirements with Optima's experts?
OPTIMA pharma | Experts for aseptic filling
OPTIMA pharma
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