Robotic filling systems such as AST’s ASEPTiCell offer several significant advantages when compared to traditional vial or syringe processing lines and include the following:
Enhanced Sterility Assurance. Robotic systems can completely automate the aseptic fill-finish manufacturing process to the degree that the operator is removed from the most critical aseptic operations. By removing the operator from the aseptic process contamination risks are reduced along with process variability that the operator could introduce.
Improved Cleanability. Traditional filling lines have many machine elements that are required to fill and close the container it is processing. Couple this with the number mechanized parts that penetrate through the machine base plate you have a maze of difficult and time consuming spaces to clean. With robotics systems the robotic arms integrated with the machine eliminate the complexity of parts and base plate penetration to process the very same container. This provides fewer parts and easy to access open surfaces that can be easily cleaned.
Fewer Change Parts. Change parts can be expensive, time consuming to place and remove from the machine and can be subject to improper setup or adjustment by the operator. Robotic systems reduce the number of formats parts required, and what change parts are required are very simple and easy for the operator to install. A trained operator can typical change over a robotic system in 30 minutes when compared to upwards of twice or more for a traditional filling machine.
Flexibility. Traditional aseptic filling equipment typically is dedicated to a single container such as a vial or syringe. Robotic systems can provide the capability of processing multiple container options such as vials, syringes and cartridges on the same aseptic fill-finish machine. In addition with the ability to process multiple container types robotic systems like the ASEPTiCell are not constrained like other systems to use specific components, such as press-fit caps, but can process a wide range of traditional components.
Minimal Particle Generation. AST integrates Staubli TX series articulating arms. These robotic arms come standard with an ISO 5 certification and can be provided with an improved rating if required. The Staubli TX series robots are widely used in semi-conductor applications that cannot tolerate particle contaminations and thus required a robot that can achieve Sub Class 1. To compliment this capability AST’s ASEPTiCell format parts are static and do not have motion outside of the robotic arm itself to eliminate and particles that can be created from sliding or rotating motion.
No Trolleys.Robotic machines have flexibility “baked into” the system and can process multiple container formats with few and simple change parts. AST’s ASEPTiCell does not require specific and dedicated machine trolleys to dock with an isolator to provide process and container flexibility. This minimizes cost, maintenance on several machines, change parts and storage space for multiple trolleys.