In the pharmaceutical sector, there is strong demand for high-performance lines with the capacity to fill, for example, up to 60,000 syringes per hour. This, after all, is a sector where frequently used medicines need to be produced quickly and efficiently for delivery to patients all over the world. However, there is also a growing demand for small-scale filling lines that can easily be reconfigured to process different medicines or containers. This is due, among other things, to the development of biotechnologically produced drugs: a trend that manufacturers of filling and packaging machines simply cannot afford to ignore.
Small footprint, maximum flexibility
Developed by Bausch+Ströbel in conjunction with Swiss isolator specialist SKAN, VarioSys offers a maximum of flexibility. This space-saving modular system owes its tremendous versatility, in part, to the possibility for combining a specialty isolator with a range of different machine modules. In addition, multiple modules can be linked together in combination with a sterilizing tunnel, cleaning machines or a freeze-dryer to create a production line. In practice, this means that the production module simply slides out of the isolator like a work bench and can be replaced with another module. VarioSys is continuously being expanded by adding new modules and applications. At the Achema 2018 Bausch+Ströbel will be unveiling a highly innovative module that makes even lighter work of processing nested syringes.
A wide range of combinable machine modules
Potentially combinable production modules include:
- A module that can be equipped with a wide variety of laboratory units or semi-automatic machines to suit individual requirements.
- A fully automatic machine for filling and closing bottles or vials (KSF 5105) or only for closing bottles or vials (KS 4105) with outputs of up to 3,600 containers per hour.
- A fully automatic, intermittent-motion machine for filling and closing ready-to-fill disposable syringes, vials or cartridges supplied in nests in tubs (SFM5105) with outputs of up to 4,200 containers per hour.
- A machine module for processing ampoules. The module can process up to 6,000 containers per hour with 100 percent IPC
To achieve maximum versatility, different dosing systems are also available. For example, peristaltic pumps or valveless rotary piston pumps can be used for liquid products or dosing augers for powder products. Single-use systems also present no problem. A special air flow configuration within the isolator also allows highly potent or toxic products to be processed safely.
VarioSys in motion: VarioSys Move
Changing modules has always been very simple with VarioSys, but now there is a new solution that makes this task even easier for machine operators. The VarioSys Move module changing system transports the machine modules automatically from the parking position to the isolator and back. An operator uses a remote control panel to bring the modules to the isolator. From here, they are transported into the isolator fully automatically and with pinpoint precision. The modules are precisely transported into the PSI‑L isolator and back into their parking position along an optical track. Once in the parking position, the modules are loaded automatically. A single transport system can be used for multiple machine modules. This allows the customer to change over quickly from one production process (e.g. vials) to another (e.g. syringes, ampoules or cartridges)
User benefits:
- Easy handling; no physical effort is required
- Precision positioning; no operator intervention is required
- The right module is always in the right place – guaranteed
- Machine modules can be navigated more easily (for safety reasons, the castors must not be designed to swivel).
Bringing new developments to market quickly
A time and space saving system for small-scale production, VarioSys can not only be converted easily – it can also combine a wide variety of components individually and can easily be adapted to new requirements by adding extensions. Moreover, this can be done with a minimum of investment and (thanks to standardization) with short qualification and validation times: a major advantage in the race to bring new developments to market.
