GENiSYS® C Automated Filling & Closing System for Vials, Syringes & Cartridges

R&D, Engineering Runs, Small Batch cGMP Filling & ClosingGENiSYS Filling and Closing System

AST’s GENiSYS® C is an advanced, yet compact, filling and closing system for automated processing of nested, custom and ready-to-use vials, syringes, and cartridges.  With many features typically found in large scale filling machines, the GENiSYS C’s compact footprint makes this system ideal for use in small scale filling applications, including R&D, process development, engineering runs, niche product manufacturing, and even cGMP clinical and small-batch commercial manufacturing.

 

Aseptic Barrier Technologies

The GENiSYS C is designed for use within a Laminar Airflow Hood (LAF), Restricted Access Barrier Systems (RABS), and aseptic isolators, making the system ideal for use in labs and clean rooms with minimal available space.  AST’s meticulous attention to aseptic design, selection of the materials and surfaces has been done to ensure that the system meets cGMP standards for aseptic processing.

  • Laminar Airflow Hood (LAF)
  • Restricted Access Barrier System (RABS)
  • Barrier Isolator Systems
Capabilities

Superior Process Flexibility

GENiSYS C is the ultimate “multi-tool” for small batch aseptic applications.  Its design provides unrivaled flexibility in a compact layout, with an intuitive and simple to operate user interface.  The GENiSYS C is designed to process nested, ready-to-use and custom vials, syringes and cartridges.  The system can be configured with advanced system features and capabilities, including peristaltic and rotary piston pumps, integrated in-process weighing (IPC), viable, non-viable and particle monitoring (EM), electronic batch record (EBR) reporting, inert gas purging, and vacuum or vent-tube piston insertion of pre-filled syringes and cartridges.

 

 

Maximize Product Yield

Eliminating waste is the key to successful small-batch processing. Necessary operations such as pump calibration, on-going fill volume checks and residual product hold-up in the fluid path all contribute to wasted product material.  The GENiSYS® C in-process control system allows for 100% fill weight inspection and real-time filling directly on the electronic weigh scale to eliminate improperly filled containers and minimize product hold-up at the end of the batch in order to maximize product yield.  Couple this with ASTView Electronic Batch Record (EBR) system and you are able to have a complete record of the dispensed product.

 

Advanced System Features:

  • In-Process Control (IPC) that provides real-time fill weight feedback and control - maximizing product yield
  • ASTView is a high-resolution interface that provides intelligent and intuitive control and real-time process monitoring of the system
  • Servo-Driven Motion control system provides accurate and repeatable filling and closing of nested vials, syringes, and cartridges
  • Process flexibility that provides multiple dispenses and closing options for syringes, vials, and cartridges
  • Aseptic Barrier options allow the system to be integrated with a Laminar Airflow Hood (LAF), RABS or isolator technology for aseptic environments
  • Electronic Batch Report (EBR) System records critical process information that can be used to create 21 CFR Part 11 compliant batch reports

 

Applications include:

  • Small to medium batch production of commercial and clinical materials
  • Filling of toxic and cytotoxic materials
  • Filling and assembly of custom devices and containers
  • R&D, pre-clinical and drug process development
  • Engineering runs
Benefits
  • Automated processing of ready-to-fill vials, syringes and cartridges
  • Up to 20 containers per minute
  • Fast and easy change-over with tool-less change parts
  • High accuracy product dosing
  • Optional fully integrated in-process weight check system
  • Multiple syringe and cartridge stoppering options
  • Viable & non-viable environmental monitoring
  • LAF, RABS or Isolator Configuration
  • High-resolution color touchscreen interface
  • Optional Electronic Batch Reporting (EBR) System
  • 21 CFR Part 11 compliant
  • IQ/OQ and GAMP documentation available
Technical Information

Machine Model:

GENiSYS® C10

GENiSYS® C20

System Dimensions

(LxWxH):

1800mm x 625mm x 1725mm

[71" x 25" x 68"]

Containers:

Pre-sterilized vials, syringes, and cartridges

(Note: Tooling for non-standard/custom container formats available)

Vial Sizes:

2mL to 50mL (ISO 2R – 50R)

Syringe Sizes:

0.5mL to 50mL

Cartridge Sizes:

1mL to 20mL

(Note: Options available for sizes not listed)

Production Rate:

Up to 10upm

Up to 20upm

Dispense Options:

Peristaltic & Rotary Piston

Filling Accuracy

Up to ±0.5% (varies with fill volume)

Vial Closing Methods

Serum or Lyo stopper options

Vial Sealing Methods

Crimp or Press-fit capping options

Syringe / Cartridge Closing Method:

Vacuum, Vent-Tube and Vent/Vac Combo

Barrier System:

Laminar Airflow Hood (LAF)

Materials of Construction:

Pharmaceutical grade stainless steel, plastics, and elastomers

Human-Machine Interface (HMI)

ASTView on a 10" color touchscreen

Available Options:

  • In-process fill weight verification (IPC) and automated dynamic pump calibration
  • Viable and non-viable environmental monitoring (EM)
  • Electronic Batch Report (EBR) system
  • Pre & post-fill container purging with inert gas
  • Extended Laminar Airflow (LAF) Hood
Machine Model: GENiSYS® C10 GENiSYS® C20
Dimensions (LxWxH)

1830mm x 622mm x 1672 mm

[60" x 24" x 66"]

Containers:

Pre-sterilized vials, syringes and cartridge

(Note: Tooling for non-standard/custom container formats available)

Vial Sizes: 2mL to 30mL (ISO 2R – 30R)
(Note: Options available for vials greater than 30mL)
Syringe Sizes: 0.5mL to 20mL
Cartridge Sizes:

3mL, 5mL & 20mL

(Note: Options available for sizes not listed)

Production Rate: Up to 10upm Up to 20upm
Dispense Options: Peristaltic & Rotary Piston
Filling Volume: 0.1mL to 250mL
Filling Accuracy Up to ±0.5%
Syringe / Cartridge Stoppering Method: Vacuum & Vent-Tube
Barrier System: Laminar Airflow Hood (LAF)
Electrical Utilities: 220/110VAC – 50/60Hz.
Human-Machine Interface (HMI) ASTView on a 10" color touchscreen
Materials of Construction: Pharmaceutical grade stainless steel, plastics and elastomers
Certifications/Compliance: CE marked
Available Options:
  • In-process fill weight verification (IPC) and automated pump calibration
  • Viable and non-viable environmental monitoring (EM)
  • Electronic Batch Report (EBR) system
  • Pre & post-fill container purging with inert gas
  • Extended Laminar Airflow (LAF) Hood

 *Figures are typical. Actual performance results and technical parameters may vary depending upon application requirements. 

**Subject to change without notice.

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