Sterile Tray with Grasping Channels for Vial Closures
Solution Overview
Problem
The manual handling of pharmaceutical vial stoppers and seals in small batch quantities poses a risk of microbial and particulate contamination due to the complexity and difficulty of unpacking bulk packaging in compact laboratory or biosafety cabinet settings, where conventional trays are not well-suited for safe and easy handling.
Innovation Solution
The development of sterile trays with a receptacle array and connection web design that allows for easy access and handling of individual vial seals and stoppers, featuring a channel for grasping and steam sterilization, and a tray configuration that minimizes contamination risk by allowing single-component retrieval without touching adjacent items, along with a tray lid for secure storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bulk packaging is used for vial closures, then manufacturing efficiency and storage space are improved, but handling complexity and contamination risk increase in compact laboratory settings
Solution Approach 1:
The bulk packaging is divided into individual single-vial trays, each containing a specific number of closures (e.g., 10 closures per tray). This segmentation allows laboratory users to handle only the required quantity for a single vial filling operation, eliminating the complexity of managing large bulk packages in compact biosafety cabinets while maintaining the efficiency of bulk manufacturing and storage.
2Ease of operation
If closures are unpacked from bulk bags in compact workspaces, then accessibility is improved, but contamination risk increases due to multiple handling steps
Solution Approach 1:
The closures are pre-arranged in individual trays with dedicated receptacles that match the vial configuration. This preliminary organization eliminates the need for users to unpack, sort, and rearrange closures during the sterile filling operation. The trays can be directly placed in the biosafety cabinet and used as-is, reducing handling steps and contamination risk while maintaining easy accessibility to individual closures.
3Quantity of substance
If conventional trays are used for bulk closures, then storage capacity is improved, but adaptability to compact laboratory settings deteriorates
Solution Approach 1:
The storage system is segmented into individual single-vial trays that can be independently handled and stored. Each tray is compact enough to fit comfortably in biosafety cabinets and on laboratory desks, while the connection web allows multiple trays to be linked for storage. This segmentation provides both compact storage capacity and high adaptability to various workspace configurations.
Solution Approach 2:
The trays are designed with universal features including a connection web for linking multiple trays, a lid for protection during transport and storage, and receptacles that accommodate standard closure types. These universal design elements make the trays adaptable to different laboratory settings, workspace sizes, and vial configurations while maintaining adequate storage capacity.
4Productivity
If multiple closures are handled simultaneously from bulk packages, then efficiency is improved, but sterility integrity deteriorates
Solution Approach 1:
The closure system is segmented into individual trays containing specific numbers of closures (e.g., 10 closures per tray), with each closure having its own dedicated receptacle. This segmentation allows operators to handle only the required number of closures for a single vial filling operation, maintaining sterility integrity by minimizing the number of closures exposed to the environment and reducing the risk of cross-contamination between closures.
Solution Approach 2:
The lids are extracted as separate protective components that can be attached to individual trays. The lid acts as a barrier that protects the closures within the tray from environmental contamination. By using individual trays with lids, operators can efficiently handle multiple closures in a single tray without compromising sterility, as the lid remains closed during transport and storage and is only opened when needed for the specific filling operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The trays provide a safe and efficient means to handle and sterilize vial seals and stoppers in small batches, reducing contamination risks and improving handling ease in compact workspaces, facilitating the assembly of pharmaceutical vials while maintaining sterility.
Implementation Method 1
a channel extending through the plurality of individually spaced-apart receptacles disposed in each respective receptacle row, the channel forming a clearance on opposing sides of each receptacle for facilitating grasping of the vial seal held in the corresponding receptacle
Data Source
AI summary
Small batch packaging for vial seals and vial stoppers is provided. The packaging includes a vial tray having a plurality of individual spaced-apart vial receptacles for receiving respective vials. The packaging also includes a vial seal tray having a plurality of individual spaced-apart seal receptacles for receiving respective vial seals. The packaging further includes a stopper tray having a plurality of individual spaced-apart stopper receptacles for receiving respective vial seals. A seal channel may extend through the plurality of individually spaced-apart seal receptacles to form a clearance for facilitating grasping of each vial seal. Similarly, a stopper channel may extend through the plurality of individually spaced-apart stopper receptacles to form a clearance for facilitating grasping of each vial stopper.