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IMA Life • Aseptic Processing and Freeze Drying Solutions

IMA Life is the ideal partner for aseptic processing lines. The product range includes blowers, washers, depyrogenating tunnels, liquid and powder fillers, freeze dryers, automatic loaders/unloaders, labellers, isolation systems.

IMA Life Updates

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IsoTech Lab: our in-house Isolator Research & Development Laboratory

The IsoTech Lab is where our unique, integrated solutions are designed, tested and developed for aseptic processing lines and freeze-drying applications.

INJECTA 36. Increasing your potential

Enhancing the performance of advanced robotics, the INJECTA 36 raises the bar for high-speed production of Ready-To-Use components.

TILE-X. Innovation goes magnetic.

Enhanced sterility assurance, gloveless efficiency, robotic accuracy. Based on electromagnetic levitation, TILE-X is a compact, Grade A, modular processing unit for high-value pharmaceuticals such as ATMPs.

NEBULA

HYPERSPEED DECONTAMINATION TECHNOLOGY

Breaking ground with unprecedented continuous processing capabilities, Nebula is a multi-chamber decontamination tunnel which integrates seamlessly with IMA Life aseptic fill-finish lines. Responding to the latest Annex 1 guidelines, Nebula accomplishes 6-log decontamination using HC-VPHP while material crosses the tunnel in a matter of seconds.

Secure sterility and accelerate your aseptic.

KRYOAIR
Refrigeration system for freeze drying

KryoAir is a new technology, 100% green refrigerant, using air as the refrigerant used in freeze dryers. The system is based on a series of compression/cooling/expansion steps of AIR, which can be cooled to a temperature as low as-100°C.

MODULA. Eyes on assembly.

With a wide range of syringes handled, IMA Life MODULA Series ensures a continuous motion principle to assemble up to 300 syringes per minute. Make your process more modular through the configurations that can be achieved thanks to the combination of its three operating units: plunger rod assembly, label application and backstop insertion. The highest automation level in a compact design.


The coolest laboratory spray freezing module.
LYnfinity starts here.

LYNFINITY LAB winner of BEST TECHNOLOGIES INNOVATION at INTERPHEX 2022 EXHIBITOR AWARDS

Setting new standards in aseptic processing

Producing more than 200 machines per year in the field of liquid and powder filling, most of which are integrated into complete processing lines and with over 1000 freeze dryers installed in over 50 different countries, IMA Life can manage large-scale projects, designing and manufacturing customised solutions to meet special end-user requirements.

IMA Life operates out of six production sites, each one specialised in a specific step of the process.

Customers are IMA Life’s core business. Understanding customers’ needs and offering service/support create a real benefit throughout the entire supply chain. The relationship with customers is what guides the way we design and develop machinery and services.

Qualified project managers follow the customers from the very beginning of URS definition through the entire project lifespan. They plan, organise, secure and manage resources ensuring that end-user time-to-market deadlines are met.

Ready-To-Use syringes, vials, and pre-capped cartridges

Fill-finish processing in an aseptic environment is a critical operation in terms of accuracy, precision and reliability. IMA Life’s new generation of highly flexible fill-finish machines for Ready-To-Use syringes, vials and pre-capped cartridges pre-arranged in nests and tubs/trays, fully responds to these requirements.

IMA Life’s compact and ergonomic solutions have recently been improved by cutting-edge robotic technologies that assure accurate no-touch-transfer component processing with minimal operator access to the working area. This replaces standard machine motions, with an aim to assuring a smooth production process, minimising occupied floorspace and drastically reducing human intervention.

Ensuring increased performance in terms of processing speed and capacity, another robotically driven fill-finish machine handles up to 36,000 syringes per hour, integrating a key technological breakthrough, the ability to perform 100% checkweighing of each of the processed RTU components with single rejection of non-conformities.

Recently launched, a high-speed decontamination tunnel that sterilises RTU components in continuous mode, achieving 6-log surface decontamination using highly concentrated vapour phase hydrogen peroxide. Heating, decontamination and purging operations are performed in a controlled environment in which temperature, H2O2 concentration and atmospheric pressure are regulated to maximise efficiency and material sterility.

The latest development by IMA Life presents a solution for small batches of high-value RTU products. It features ground-breaking technology providing an effective response to Annex 1 requirements thanks to its totally gloveless processing capabilities. 

Aseptic processing for vials and ampoules

One of the major challenges for IMA Life is to implement the latest technologies in aseptic filling, whilst ensuring compliance with the highest cGMP’s standards in filling accuracy.

From the decontamination of containers, through depyrogenation, up to filling, closing and capping operations, all our efforts are targeted to avoid any possible contamination risk while managing a wide range of toxic and biological risk product types at the highest performance.

The very compact and versatile design of IMA Life machines for filling liquids into vials and ampoules and powders into vials, allows for suitable integration under isolator or different containment solutions without changing the basic machine configuration and minimising human intervention in the processing area. Fitting an unlimited number of modular layout configurations, our isolated solutions ensure the necessary versatility to adjust the production process according to customer needs and maximise line performance up to 600 units/min. with 100% In-Process Control.

The external washers complete the range and fit the market’s increasing demand for decontamination solutions to remove product particles from the outside of vials and ampoules.

IMA Life’s IsoTech Lab (at Bologna HQ) is where our unique, integrated solutions are designed, tested and developed for aseptic processing lines and freeze-drying applications.

Freeze drying and lyophilisation processes

For more than half a century, IMA Life has provided the benchmark for freeze drying solutions to the pharmaceutical and biotech industries. The machine range includes industrial FD, solutions for pilot work or clinical trial production or even R&D laboratory freeze dryers. These last freeze dryers are available for the USA and Canadian markets only.

This wide range of custom-built freeze dryers is available as stand-alone units or integrated in complete lines including automatic loading and unloading systems for vial transfer.

IMA Life’s steady investments in R&D initiatives (LAB4LIFE lyo development laboratory at our facility in Tonawanda, US) have resulted in innovative solutions in the lyophilisation process and technologies such as:

  • Advanced innovative controlled nucleation technology capable of producing sterile cryogenic ice fog (Ice Fog Nucleation)
  • In-house lyo shelves using an automated manufacturing process to ensure lower operating costs, enhanced process control and reduced risk.
  • Further improvement of the lyo shelf traditional technology to avoid sticking stoppers. This proven solution consists of a low-adhesion coating applied to the lower shelf surface and it is patented worldwide.
  • New 100% green refrigerant, using air as the refrigerant used in freeze dryers. The system is based on a series of compression/cooling/expansion steps of AIR, which can be cooled to a temperature as low as -100° C.
  • IMA Life’s cloud-based system for freeze-drying data analytics and health monitoring.
  • Mass spectrometry, a multipurpose device performing quantitative, real-time, process-relevant measurements.
  • Spray freeze drying technology which brings to the market a robust yet gentle continuous aseptic process.
  • Laboratory unit for spray freezing technology, designed for lab environments, featuring the same freezing process present on the production configuration, generating uniform frozen droplets from liquid formulation.

Aseptic and non-aseptic bottle processing

Suitable for aseptic and non-aseptic environments, IMA Life bottle fillers can dose different types of products such as ophthalmic drugs, intranasal products, infusions, preparations, suspensions, oral drops, drinkable sugary syrups, detergent/disinfectant solutions, etc. They can also apply different types of closures such as screw caps, push-on caps, droppers, reducers, pumps, dip tubes, ROPP caps, etc.

Robust, efficient and safe, these machines are capable of producing under extreme load conditions, ensuring high output requirements.

Designed to function as stand-alone machines, they also work perfectly as integrated solutions, under isolator or with other containment technology, and represent IMA Life’s response to the demands for flexibility, modularity and reliability expressed by today’s pharmaceutical market.

Labelling and serialisation

The IMA Life production range includes a vast array of linear and rotary labelling machines for vials, ampoules, bottles, blow-fill-seal containers and cartons.

Supplied in stand-alone versions or as an integral part of complete packaging lines, they can apply any kind of self-adhesive labels (wrap-around, front, rear or both sides) on standard or irregularly shaped plastic or glass containers, as well as vignette and tamper-evident sealing on both aeroplane style and reverse tuck cartons.

These machines feature different solutions to align the packaging of pharmaceutical products to emerging requirements in terms of Track & Trace of the final products.

Thanks to the configuration flexibility of the operative groups, the labelling machines can fit overprinting devices and camera vision systems to read and check data.

IMA Life Service Solutions

IMA Life provides a complete set of services designed to assist customers in several areas and improve their overall performance. Highly skilled professionals, cutting-edge laboratories and full support before, during and after installation.

Service Portfolio

The full service offering encompasses a multitude of specially developed packages to boost production efficiency, anticipate maintenance requirements or implement rapid corrective measures. A vast selection of training modules for key operational aspects also covers process yield and quality control as well as giving technological insight into the machinery. To complete the services provided, IMA Life also supports customers with equipment upgrades, total overhaul and line relocation.

IsoTech Laboratory

Located in Bologna (Italy), at the IMA Life facility, this laboratory is specifically conceived to perform internal research and to develop activities/training sessions in cooperation with customers. Equipped with machines under isolator, customers can carry out tests in the presence of our engineering staff and sterility assurance team to evaluate performance and determine optimisation opportunities.

Lab4Life Laboratory

Located in Tonawanda (USA), at the IMA Life North America facility, the Lab4Life Laboratory consists of a certified clean room, analytical support laboratory, product formulation, filling and full-size freeze drying equipment necessary for the development of pharmaceutical and biopharmaceutical products in batch sizes up to 20 litres. The laboratory includes a highly skilled team of professionals who provide assistance to our customers worldwide.

Registered Office & Production Facility:

Via Maestri del Lavoro n. 203 – 40024 Castel San Pietro Terme (Bologna) – Italy
Tel. +39 051 0296111

Production Facilities

IMA Life Calenzano • Via Francesco Petrarca, 34/40 – 50041 Calenzano (Firenze), Italy
Tel. +39 055 883231 

IMA Life PharmaSiena • Via Benedetto Zalaffi, 1/3 – Zona Industriale Renaccio – 53100 Siena, Italy
Tel. +39 0577 247720 – 379053

IMA Life North America • 2175 Military Road – Tonawanda – NY14150, U.S.A.
Tel. +1 716 695 6354 

IMA Life Beijing • No. 3 JianAn Street, BDA (Yizhuang) – 100176 Beijing, People’s Republic of China
Tel. +86 10 596 23866 899

IMA Life Shanghai • 3590, Caoying Road – Qingpu district, Shanghai, People’s Republic of China
Tel. +86 210 59228825

FD Service Centers

IMA Life Division • Via Piero della Francesca, 26 – 20090 Trezzano sul Naviglio (Milano), Italy
Tel. +39 02 36566993 

IMA Life The Netherlands B.V. • De Leest 3 – 5107 RC Dongen, The Netherlands
Tel. +31 162 383500

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