BABY PHILL is conceived for any customer who need a Plug&Play technology who require a short product placement on the market. The 100% IPC control of the dosing guarantee a high quality of the final product.
The newest model of BABY PHILL has seen a deep redesign, with increased speed up to 2,500 vial/h (based on 10ml/10R and 8ml filling volume).
BABY PHILL is designed for filling of RTU ( ready to use) vials in trays.
BABY PHILL can also be connected with small vial washing machine and depyrogenation tunnel for bulk production.
Key performance values for fill finishing
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Short lead time
Pre-Designed
Fast manufacturing |
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Proven Technology
Best In Class – GMP Guidelines adherence
Robustness Isolators & Filling machine |
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Small Footprint
Compact Modular design
Easy to replicate also in limited spaces |
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Flexibility
Suitable for different Products
Suitable for different Process |
Product & Packaging Material
- The BABY PHILL has been specifically designed for Aseptic Liquid Filling
- It can be used for small batches, with RTU Vials in trays
- As alternative it can be linked to Washing machine & Depyrogenation tunnel, for medium size batches
- Automatic or semi automatic loading and accumulation of vials on rotating table
- Wide range of vials can be adopted, with minimum format changes and short time impact
A real smart approach
Thanks to its modular design, the filling line is available with different possible configurations in order to fulfil the requirements of different production needs.
Bag Removal & No Touch Transfer
- ORABS for Debagging & No-Touch-Transfer or Vial Washer & Depyrogenation Tunnel
- Fast Decontamination Chamber
- Easy waste bag management
- Tray Inversion System
- Manual or Automatic feeding
Vial Feeding & Rotating Table
- Manual feeding from NTT, or direct link with Washing machine & Tunnel
- Minimum and max load sensors
- Central opening for better air flow, less turbulence
- Servo driven, adjustable speed
- Easy change over of format parts
- Vial trap and reject station for upside-down vials
- Walking beam entrance with vial optical counter
Filling & Stoppering
- Linear Transport System, walking beam
- Peristaltic or Volumetric Piston Pumps, or both
- No Vial – No Fill function
- 100% IPC with Load Cells (tare & gross)
- Nitrogen Injection, during and/or after filling
- Pick & Place Stoppering System, with stopper presence detection
- Independently Servo Driven Filling function
- 1 + 1 Filling pump, for double shot filling (large volume > 20ml)
- Independent filling volume per each pump, adjustable from HMI
- Easy change over, from piston to peristaltic (both systems)
- Diving needle holder, bottom-up filling available
- Priming function included, with less product loss (fill to weight)
Capping Station
- Suitable for Flip-off, Tear-Off or Press-on Caps
- Idle Ring sealing System, less particles generation
- Partition wall between filling-stoppering & capping station, with mouse hole
- Cap presence detection No Vial – No Stopper – No Cap function
- Suitable for all format size, 2R-100R
- Pressure control during capping available as option
Reject Station & Exit on Trays
- After Cap sealing an indexing star wheel separate the good vials from the sample vials and the eventually rejected vials (no stoper; no cap; out of tolerance)
- The vials are directed to a dedicated RTP port, connected with waste bag or a sampling container
- The good product is accumulated at the machine outfeed on a removable tray
Available Accessories
Rotary intermittent washer by DF Siena
The rotary intermittent washer is a fully automatic, intermittent motion, rotary washing machine, suitable to wash and clean brand-new containers, such as vials. The rotary washing machine is developed to handle vials in order to permit the internal and external decontamination of the containers.
Operating cycle
The loading section is composed by a dead plate, directly connected with a rotary table, here the operator can push the vials from the plastic tray to the loading station. The washing system has plunging needles with the possibility of varying the phases and times of the fluid dispensing.
Washing cycle
The rotary intermittent washing machine is proposed with a standard washing cycle is completely modifiable in the media order/type and programmable as washing times depending on items to treat and/or availability of washing media.
- Pincers loading
- Blowing with filtered compressed air – INT
- Washing (PW or WFI) – INT/EXT
- Blowing with filtered compressed air – INT
- Washing (PW or WFI) – INT
- Blowing with filtered compressed air – INT/EXT
- Washing (WFI) – INT
- Blowing with filtered compressed air – INT
- Dripping and unloading.
Depyrogenation tunnel by DF Siena
Depyrogenation tunnel guarantees the continuous sterilization and depyrogenation of glass containers such as vials, type R or type H, by means of filtered high temperature air (max 350°C) in laminar flow conditions.
The air laps vertically the containers, with uniform increase of the heat, achieving a shorter time sterilization process.
Infeed zone
A vertical laminar flow protects the tunnel entrance from the external contamination, and avoids the coming out of the hot air.
The air is prefiltered, HEPA filtered and then flows over the vials in laminar condition, at a speed adjusted around to 0,4 – 0,5 m/s, with air speed measurement.
Depyrogenation zone
The chamber is made by stainless steel shell, externally protected by approved insulation materials (ceramic). The tunnel is provided of a variable number of HEPA filters for high temperature (max 350°C).
In the depyrogenation chamber the air is fully ricirculated. For each filter, a fan placed in the bottom of the tunnel, sucks the air out from under the conveyor belt (in the coolest point of the recirculation loop) and blows the air towards the heaters, placed along the supply duct, directly on the equalization system, through the filters and, finally, on the vials. In this way there is a pressure increase in the air flow just for the temperature increase, with less efforts in the fan functioning and a longer device lifetime.
The air speed is adjusted and controlled with optimal unidirectional flow conditions.
The max temperature set-point is 350°C. In order to save energy and to not overheat the glass, each type of vial is processed with the suitable time/temperature setting to achieve the desired depyrogenation degree.
Cooling zone
In the cooling module the air is sucked from the room. The air is first pre filtered, HEPA filtered and the air speed is adjusted and controlled with optimal unidirectional flow conditions.
Integrated Solution With Isolator Barrier Technology
- Possibility to operate in Positive or Negative pressure regime (monitoring & alarms)
- Airborne Particulate cleanliness classification: ISO 5 for internal environment
- Laminar Air flow system (Zero Frame) for 0,45m/s
- HEPA or ULPA filtered air supply
- Recirculation up to 70% of the air flow
- Continuous Monitoring: Diff. Pressure, Temp, RH%
- Preliminary CFD Engineering Study
What makes Baby Phill special?
- Extremely reduced footprint, so it can be easily fit in your existing lab
- Plug-and-play design, suitable for fast installation and start production
- All-in-one system, so all key features are included as standard
- Different dosing systems available, peristaltic or piston pumps
- Best integration within isolation technology, as Comecer designs and manufactures both
- Fast change over between batches, to make the most of your investment and time
- Possibility to integrate and connect with Freeze Dryer System
- Outstanding value proposition, in terms of flexibility, overall quality, price and readiness on the market
Customized configurations
The Baby Phill can be configured with different upstream and downstream ancillary systems to build the complete package. From the vial loading prechamber, the washing and depyrogenation systems, to vial outlet, the different solutions are implemented in order to fully address the specific applications.
Optional equipment
- Class A Isolator or RABS
- “Speedy Glove” glove integrity testing device
- Loading chamber
- Unloading chamber lyophilizer charging/discharging
- Integrated lyophilizer
- Sterilization and depyrogenation tunnel
- Vial washing machine
- Integrated VPHP generator for automatic decontamination
- HVAC for independent air treatment (RH & T)
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