Didn’t catch the innovative solutions unveiled by AST at INTERPHEX 2026? Don’t worry; we have you covered with our annual INTERPHEX recap.
In-booth demonstration of the GENiSYS R
The AST team presented end-to-end demonstrations of the latest GENiSYS R, a modular fill-finish system designed for the flexible processing of ready-to-use vials, syringes, and cartridges with the minimal use of change parts. The booth featured a fully automatic, hands-free configuration of the machine for the filling, closing, and sealing of nested vials. Onlookers were able to observe the entire process, starting with the Automatic Bag Opening (ABO) and Automatic Tub Opening (ATO) modules that prepped the RTU tub of vials for processing. Filling and closing were carried out in the Fill-Close Module (FCM), where visitors could take an in-depth look at the smart visual and sensor technology used to ensure product quality, process accuracy, and repeatability. Automated features like real-time weight checks, restoppering, and reject sorting were also demonstrated. The final stop at the GENiSYS R was the Vial Sealing Module (VSM), where containers were sealed in accordance with Annex 1. The VSM demoed a spinning-disk crimp for a pharmaceutical-grade seal and highlighted the standard and linear outfeed options available in the module.
Expertise in Action: CQV Principal Engineer Jason Rossi presents at the INTERPHEX Learning Lab.
AST’s Principal CQV Engineer took the stage at INTERPHEX 2026 to discuss approaches to modern facility designs for sterile product manufacturing. With a continued emphasis on holistic, quality-by-design implementation and relevant expertise and skills in demand across the industry, pharmaceutical manufacturers are looking for resources and partnerships that enable comprehensive and seamless cGMP operations. The momentum of the latest biopharmaceutical products, combined with advancements in aseptic manufacturing processes and technologies, will continue to provide the pharmaceutical industry opportunities to innovate towards higher standards of quality and sustainability. More than ever, there’s a need for a holistic design of the entire aseptic manufacturing operation, from the initial project planning and facility design to the filling process and downstream operations.
As regulatory emphasis and product demands continue to spotlight the comprehensive design approaches, strategies are needed that connect product quality initiatives with robust solutions for operational efficiency and sustainability. Jason covered the latest holistic design approaches for aseptic manufacturing, from initial project planning and facility design to GMP filling, drawing on over 20 years of best practices, insights, and lessons learned.
AST Academy
Rossi also had the opportunity to connect with visitors in-booth on AST’s aseptic and CQV training and service program, AST Academy. With the addition of the expansive program, AST now provides training, services, and consulting for the full scope of commissioning, qualification, and validation to support drug manufacturing start-up and life-cycle management, in addition to a portfolio of cutting-edge aseptic processing solutions. AST Academy tackles the key operational challenges and GMP milestones leading up to production and beyond. From GMP facility design, installation, and qualification of the fill line, to overarching QRM initiatives, there’s a growing need for comprehensive strategies that address process and regulatory requirements for sterile drug products throughout the entire product lifecycle.
The program includes standalone aseptic and CQV training, including cGMP documentation, protocol development, smoke studies, intervention planning, and aseptic process design for equipment and facilities. Customizable service and training packages are also available, including a comprehensive accelerated project ramp-up.
Stäubli Features AST’s Cart-Based Vial Sealing Solution
Stäubli, a leader in robotic automation, featured AST’s cart-based vial sealing solution, the VSM-C, in-booth, where onlookers saw Stäubli’s Stericlean 6-axis robot in action, transferring vials from the nest to the crimping station. The VSM C is an Annex 1 compliant solution, offering scratch-free, pharmaceutical-grade sealing for vials. AST’s cart-based processing modules, which include the GENiSYS C cart along with the vial sealing modules, feature all the same innovation and advancements of our integrated fill-finish lines. These compact yet powerful systems provide cGMP processing at a smaller operational footprint, making them the right fit for any type of facility, from CDMO to compounding pharmacy settings.
AST was thrilled to connect with so many customers, partners, and industry friends at INTERPHEX 2026. The week was filled with excitement, expertise, and highlights of the latest developments in pharma and biotechnology, and, as always, provided a comprehensive preview of what lies ahead for the life sciences manufacturing industry.
