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Check list for the Integration of Lyophilization and Aseptic Filling Equipment

  • Writer: vincenzo esposito
    vincenzo esposito
  • May 22, 2020
  • 2 min read

Combining lyophilization and aseptic filling processes presents some design challenges, regardless of the integration of one or more equipment manufacturers. Some of the most intuitive points can be: working heights, transitions, vial conveying methods, control panels, utilities, maintenances access, alarms, pausing the line, etc… but there are some others to consider during the engineering phase:

  • Loading and unloading method (automatic, manual, pizza door, isolator integration)

  • Automatic loading system: row by row or flexible loading

  • Filling line filling speed for different vial sizes

  • Loading and unloading speeds for different vial sizes

  • Speed limitations due to vials stability in movement

  • Multiple or single lyophilizer loading and unloading system

  • Layout design: filling and capper location respect the lyophilizer

  • Layout considerations for future expansions with new lyophilizers

  • Lyophilizer unloading side

  • Single or multiple floor installation

  • Side mounted condenser

  • Vertical or horizontal condenser

  • Single skid or multiple skidded system

  • Determining conveying method for vials with liquid fill products: Bypassing lyophilizer for liquid filling

  • Integration of vial rejection system according to parameters: stopper position, missing stopper, color variation and sampling.

  • Lyophilizer CIP system

  • Bridge plate design for loading and unloading vials into the lyophilizer chamber

  • Provisions for the stoppering/shelf movement system ram assembly removal

  • Protection of vacuum system of contamination

  • Sterilization process (door seals, ram bellows, chamber and condenser)

  • Vent filter automatic or manual integrity test

  • Maintenance door side

  • Nitrogen blanketing (chamber and heat transfer fluid expansion tank)

  • Cold shelf loading

  • Integration of 100% headspace analysis to eliminate the risk of faulty vials

  • Maintenance access plan for all components



A specific section should be dedicated when the lyophilizer and the aseptic filling line are integrated with an isolator. In this case, it is important to underline a new list of points to consider.


  • Determine all gloved operations

  • Ergonomic considerations: Isolator mock-up

  • Isolators modules interconnection (mouse hole)

  • Sealing mechanism

  • Cleaning and decontamination

  • RTP ports

  • Filling stopper and capper feed bowls

  • Isolator sterilization (VHP)

  • Decontamination method (deactivation/biowaste system or process waste)

  • Air handling system and filtering system

  • Negative or positive pressure in isolator

  • Glove breach system

  • Isolator CIP

  • Inert atmosphere in isolator

  • Oxygen detection

  • Temperature control

 
 
 

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