Vial Filling Equipment - ASEPTiCell® i100

Aseptic Filling

Aseptic filling is the process of taking a sterile (aseptic) product and packaging it in a sterile container, such as a vial, syringe or cartdrige, in a way that maintains sterility.

The trend of pharmaceutical and biotechnology products requires flexible aseptic production systems that can efficiently process medium sized clinical and commercial batches without compromising quality.  The ASEPTiCell® i100 provides unrivaled flexibility for aseptic filling production of ready-to-fill vials, syringes, and cartridges with a single machine.  ASEPTiCell® i100 provides the right balance of flexibility with advanced system features to make it an ideal solution for Contract Manufacturing Organizations (CMOs), biotech and pharmaceutical companies.

ASEPTiCell® i100 can be integrated with isolator-barrier technology to make the equipment the right choice for processing of aseptic, toxic and cytotoxic applications.  Integration with advanced process features such as automated bag and tub opening, statistical or 100% in-process fill weight control provide a completely automated “hands-off” system from start to finish.

Vial Filling Equipment

Vial Filling MachinePharmaceutical vial filling equipment plays an important role in production; filling of vials and bottles in a sterile and safe environment. This type of equipment ensures that quality control is maintained throughout the production process, decreasing product loss and more importantly to make sure volume levels stay consistent.  

Syringe Filling

In today's pharmaceutical market the trend is leaning more towards prefilled syringes. Patients benefit greatly from healthcare professionals that can provide a safe and consistent product. Pharmaceutical companies can also provide a diverse product line the market sorely needs.

Why a Prefilled Syringe?

  • Safety - eliminates the risk of needle stick injuries, cross contamination, and cross infection
  • Very easy to use and cuts down on administration steps
  • Consistency and security of dosage amounts

Business Advantages

  • Savings - reduced product waste in clinical trials versus vials
  • Simple storage and disposal
  • product diversity versus vials

Applications include:

  • Small to medium batch production of commercial and clinical materials
  • Biologics, proteins and potent products
  • Multi-product aseptic filling facilities
  • Filling of potent, toxic and cytotoxic materials
  • Filling and assembly of custom devices and containers
Technical Information

Advantages of ASEPTiCell® i100

The ASEPTiCell® i100 is a multi-formation aseptic fill-finish system specifically designed for pharmaceutical and biotech products.  The ASEPTiCell® i100 integrates proven industry technologies such as robotic and isolator-barrier technology to fill and finish pre-sterilized, ready-to-fill vials syringes and cartridges on a single platform.  In addition to these core system features, automated bag and tub opening, statistical and 100% in-process fill weight verification and vial capping completely automate the aseptic fill-finish process.  This “hands off” solution enhances system productivity, and controls contamination risk by minimizing operator interventions to the greatest extent possible.

The innovative implementation of robotics provides unique advantages that minimize cleaning effort, air flow disruption over open containers, and wasted drug product.  The robotic filling allows for statistical and 100% in-process fill weight measurement with each container being filled directly on the load cell in real-time.  Upon completion of the filling process the container is immediately closed.

Downstream operations downstream of the ASEPTiCell® i100 can include lyophilizer loading and unloading and vial capping depending upon product and application requirements.

ASEPTiCell® SA is a compact aseptic filling system specifically designed for small to medium batch manufacturing of parenteral drug products. It is capable of filling, closing and sealing ready to use vials, syringes and cartridges on a compact, robotic platform at the highest levels of sterility assurance. It is the perfect solution for late stage clinical trials or commercial manufacturing of small to medium size batches of orphan drugs, tailored therapies and biologics.


Technical Information

Machine Model:

ASEPTiCell® r25/i25

ASEPTiCell® r50/i50

ASEPTiCell® r100/i100

Approximate System Dimensions (LxWxH):

4850mm x 1800mm x approx. 2750mm

[190" x 71" x 108"] 

5325mm x 1800mm x approx. 3000mm

[210" x 110" x 118"] 

5325mm x 1800mm x approx. 3000mm

[210" x 110" x 118"]


Pre-sterilized vials, syringes and cartridges

Vial Sizes:

2mL to 30mL (ISO 2R – 30R)

Syringe Sizes:

0.5mL to 20mL

Cartridge Sizes:


Production Rate:

Up to 25 containers per minute

Up to 50 containers per minute

Up to 120 containers per minute

Dispense Options:

Peristaltic & Rotary Piston

Filling Volume:

0.1mL to 250mL

Filling Accuracy:

Up to ±0.5%

Syringe / Cartridge Closing Method:

Vacuum & Vent-Tube (Mechanical)

Electrical Utilities:

230/480VAC - 50/60Hz.

Barrier System:

Restricted Access Barrier System (RABS) or Isolator

Restricted Access Barrier System (RABS) or Isolator

Restricted Access Barrier System (RABS) or Isolator

Module Options:

  • Automatic Bag Opening (ABO)
  • Automated Tub Opening (ATO)
  • Lyophilization Prep / De-Nesting Module (LPM)
  • Vial Sealing Module (VSM)

Available Options:

  • In-process fill weight verification (IPC)
  • Viable and non-viable environmental monitoring
  • Electronic Batch Reporting (EBR)
  • Pre & post-fill container purging with inert gas

*Figures are typical.  Actual performance results vary depending upon application requirements.

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