Aseptic Pharmaceutical Container Filling with Sequential Closure
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Solution Overview
Problem
Current methods for filling and sealing pharmaceutical containers are inefficient, particularly in maintaining sterility and applying uniform closure forces, leading to contamination risks and occupational hazards due to the need for simultaneous closure application and high total load forces.
Innovation Solution
A novel method and apparatus for aseptically filling and sealing multiple nested containers using a shuttle and manipulator system, which decontaminates and positions containers and closures in a controlled environment, allowing for individualized closure application and reduced exposure to contamination, utilizing a rotatable wall and closure transfer device for efficient and precise sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If simultaneous closure application is used to seal multiple containers, then sealing speed is improved, but closure force uniformity deteriorates and total load force becomes excessively large
Solution Approach 1:
The closure application process is segmented into individual sequential operations for each container rather than simultaneous application. The manipulator system applies closures to containers one at a time, allowing precise control of closure force for each individual container while maintaining high overall productivity through rapid sequential processing.
Solution Approach 2:
The system uses a dynamic manipulator with programmable motion control to adapt the closure application process. The manipulator can adjust positioning and force application dynamically for each container, ensuring uniform closure force while maintaining rapid processing speed through optimized motion sequences.
2Productivity
If conventional conveyor belts are used for processing multiple containers, then processing capacity is improved, but cleanability and sterility maintenance deteriorate
Solution Approach 1:
The conveyor belt system is extracted and replaced with a manipulator-based handling system. The manipulator picks and places containers and closures without requiring continuous conveyor surfaces, eliminating the cleanability issues associated with conveyor belts while maintaining the ability to process multiple containers through automated sequential operations.
Solution Approach 2:
The manipulator acts as an intermediary between container supply and closure application stations. It provides sterile, controlled transfer of containers and closures without direct contact with non-sterile surfaces, maintaining sterility while enabling high-capacity processing through automated handling.
3Device complexity
If nested containers are used to reduce handling complexity, then device complexity is reduced, but de-nesting and re-nesting operations increase processing time
Solution Approach 1:
Containers and closures are pre-nested in their respective nests before the filling and sealing process begins. The system is designed to work with this pre-arranged configuration, allowing rapid access to individual containers and closures without requiring de-nesting operations during the critical filling and sealing phases.
Solution Approach 2:
The nested container system serves multiple functions: it provides sterile packaging, organized storage, and ready-to-process configuration all in one structure. The manipulator system is designed to interface with this universal nested format, eliminating the need for separate de-nesting and re-nesting operations by working directly with the nested configuration.
Data Source
AI summary
There is described a method of aseptically filling a plurality of nested containers with a pharmaceutical product and applying closures to filled containers in an aseptic environment, said method comprising: removing any coverings from the nested containers and nested closures; locating the uncovered containers laterally adjacent to the closures on a shuttle; moving the uncovered containers and uncovered closures to an aseptic filling zone; transferring the uncovered containers and closures to a multi-nest holder; locating the uncovered containers laterally adjacent to a plurality of closures in the multi-nest holder; filling the containers with a pharmaceutical product; removing a closure from the nest of closures into a closure transfer device; moving the nest of filled containers beneath the closure transfer device; and removing a closure from the closure transfer device into the filled container thereby scaling the filled container.