RADIO FILL
Large batch production aseptic vial filling system

Product & Packaging Material

• The Radio Fill has been specifically designed for Aseptic Liquid Filling
• It can be used for big batches, with RTU Vials in trays
• 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
• Automatic or semi automatic discharging systyem of filled vials.

Radio Fill is compatibile with Arayamond® RayDyLyo cap for vials.
RayDyLyo® is the new all-plastic push-fit cap for closing vials of injectable drugs. Unlike alternative to the aluminum crimp cap, RayDyLyo® makes it possible to pre-assemble the stopper in the cap and simplify the production process. It allows pharmaceutical companies to accelerate the time to market of new drugs.
In alternative to the rayDyLyo can also be evaluated the Vials with Aluminium caps. In this case in process should be added a crimping station.

Radio Fill Highlights

• Modular platform for automatic filling of large batch
• Aseptic environment
• Filling speed: up to 40 pcs/min
• Filling accuracy: +/- 1%
• IPC 100% check weighing
• No Vial – No Fill system
• Flexible closure system compatible wih Stopper / AluCap / PushFitCap
• Reject station (camera for stopper/caps)
• Plug and Play

Integrated Solution with shielded hot cells

• Possibility to operate in Positive or Negative pressure regime (monitoring & alarms)
• Airborne Particulate cleanliness classification: ISO 5 for internal environment
• Unidirectional 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.

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 and Sealing 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.

Vial Extraction System

• 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 discarded vials are inserted in special lead containers and removed from the production line at the end of the batch
• The good vials are inserted in the shielded containers and they are accumulated at the machine outfeed on a removable tray.

What makes Radio Fill 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.