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#flexibility

A move closer to perfection

 INJECTA’s strategy of flexibility reflects the need to remain flexible to keep up with changing, patient-centric demands for new drug-delivery systems that can better fit patient lifestyles.

If the primary goal in the current injectable market is to achieve flexible production in a safe, aseptic environment, implementing cost-saving solutions to reduce time-to-market, INJECTA is the winning move. The use of specialised capabilities and the implementation of emerging robotised technologies create a new set of sterilisation, handling and filling challenges, improving product quality and manufacturing efficiency.

The result is “less time” spent validating aseptic conditions and superior agility for multi-product manufacturing: no size part changeover, rise of process capacity, minimal product loss, reduced human intervention, smaller footprint.

#Flexibility is Multi-Product and Multi-format Handling.

INJECTA’s high flexibility for multi-product and multi-format handling enables rapid switches between different drugs and the product’s primary packaging.

  • Feeding by Tub/Nest
  • Feeding by Tray
  • Feeding by Bulk

INJECTA is born to be flexible.

Its filling system can accommodate a wider range of containers like tubs, nests, trays and pre-sterilised RTU components such as vials, syringes and pre-capped cartridges, pre-oriented vials in trays as well as sterilised vials from the depyrogenation tunnel (bulk feeding), allowing high process flexibility and adaptability. No need to change the filling module and minimal/no size changeover is required thanks to INJECTA’s flexible production methods.

#Flexibility is Robotic Revolution.

Whereas conventional attempts to use robots are typically confined to just one step of production, i.e. simply for moving vials from station to station or for removing the cover from a tub of nested containers, INJECTA uses the full potential of its robots.

INJECTA uses the full potential of its robots.

The use of advanced robotically driven manipulations throughout all production operations, from outer/inner bag opening to the stoppering station, allows for a very smooth production process, drastically reducing human interventions and cross-contamination risks; all issues are solved through robot interactions. INJECTA is designed as a whole, exploiting all robotic capabilities in an integrated system. Kawasaki’s seven-axis robot arms are designed for the lowest particle shedding. They are resistant to positive/negative and high pressures and fully compatible for decontamination using H2Ovapour.

INJECTA’s specialised robots not only provide precise, consistent handling activities, but also offer a high level of flexibility: they are completely digitally controlled with Industry 4.0 capability.

 

#Flexibility is the Highest Performance in Aseptic Fill-finish Processing.

INJECTA is designed to be flexible in aseptic processing. It can easily combine and perform a fully robotized 100% check-weighing for:

  • in-nest configuration
  • de-nesting configuration.

INJECTA accurately and efficiently fills and closes RTU components in a nest or with de-nesting.

As a de-nesting solution, INJECTA’s flexible handling units allow for precise removal of components. Individual components are filled, check-weighed, stoppered and then replaced into the nest, in the case of syringes and cartridges, or transferred by a conveyor belt to complete the process.

De-nesting operations are available for high-level quality control, with individual component handling by a robot.

All processed RTU components are individually check-weighed (in the case of de-nesting) or check-weighed all together while in nest, with single rejection of each individual non-conformity, safeguarding the nest.

All the operating units are located in a remote position from the product path with easier access to filling and stoppering areas from both sides of the machine.