VarioSys - Quick conversion on the lock-and-key principle

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Any combination of numerous components create versatile production modules

A small, space saving line for processing a wide variety of products and batches inside an isolator – and that in quick succession thanks to the extremely short conversion times: this is now feasible with the versatile production modules VarioSys, developed by Bausch+Stroebel together with the isolator specialist Skan.

The principle behind this new solution is extremely simple in practice: in a special isolator enabling production in clean room class A conditions, individual production modules can be installed that fit on the lock-and-key principle - for instance a machine for processing syringes in nests or a filling and closing machine for vials. A freeze-dryer can also be integrated. Installation effectively means here that the respective production module simply slides out of the isolator like a work bench and can be replaced by another one. To ensure that the connection between the isolator and the production module is sealed securely and hermetically a special seal is inflated in the L-flange. The quick airlock SARA permits material transfers into and out of the isolator safely and effectively. There the decontamination with hydrogen peroxide (H2O2) runs completely independently of the isolator and only takes 15 minutes on average.

Available production modules are for example:

  • a production module that can be equipped with a wide variety of laboratory units or semi-automatic machines to suit the individual requirement.
  • a fully automatic, universal machine for filling and closing (KSF 5105) or only for closing (KS 4105) bottles or vials at an output of up to 2,000 containers per hour.
  • a fully automatic, intermittent-motion machine for filling and closing ready-to-fill disposable syringes, vials or cartridges supplied in nests in tubs at an output of up to 4,200 containers per hour (SFM5105). For this application an automatic tub unpacking system can also be connected to the system.
  • further modules for stability tests, product formulation, etc.

To achieve maximum versatility, different dosing systems are also available. For example peristaltic pumps or valveless rotary piston pumps can be used for liquid products or dosing augers for powder products. Single-use systems also present no problem. A special air routing inside the isolator also permits safe processing of toxic products.
VarioSys is not only versatile from the point of view of the multiple applications, but also because the entire system is self-contained and can easily be moved to a different location. As it has no particular requirements on the site, it is immediately operational ("plug and play").
This time and space saving system for the production of small batches can be converted quickly, can combine highly differing components individually and can be adapted to suit changing situations by adding extensions - nevertheless with modest investment costs and (thanks to standardization) short validation time. A decisive advantage in the race to put new developments on the market.

Interpack 2014 impressions

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The Interpack 2014 in Düsseldorf got off to a good start for the special machine manufacturer Bausch+Ströbel from Ilshofen. Already in the first few days many customers visited the stand and numerous interesting projects were discussed. Order contracts have also been signed already. For example a syringe processing line amounting to € 1.5 million has been sold for export to Taiwan as well as another major production line for southeast Europe.

The new developments exhibited by Bausch+Ströbel on the 680 square meter stand are encountering great interest. A complete high-capacity ampoule processing line is on display at the Bausch+Ströbel stand, showing all the working steps from cleaning to filling and sealing at high speed. A new development is the vial filling and closing machine type FVF5063, which fills up to 24,000 vials per hour and closes them with stoppers - and that at 100% IPC (In-Process Control) at full output. On this machine the recently developed single-hose peristaltic pump can be viewed in action. The filling and closing machine KCP5060 has been designed especially for the production of small batches. The vials, syringes or cartridges filled and closed on this machine are transported into the working area by special clean room robots. A small, space saving line for processing a wide variety of products and batches inside an isolator – and that in quick succession thanks to the extremely short conversion times: this is now feasible with the versatile production modules VarioSys, developed by Bausch+Ströbel together with the isolator specialist Skan. The principle behind this new solution is extremely simple in practice: in a special isolator enabling production in clean room class A conditions, individual production modules can be installed that fit on the lock-and-key principle - for instance a machine for processing syringes in nests or a filling and closing machine for vials. A freeze-dryer can also be integrated. Installation effectively means here that the respective production module simply slides out of the isolator like a work bench and can be replaced by another one. Numerous further exhibits provide a good overview over the product range made by Bausch+Ströbel.
The two storey B+S exhibition stand is part of the joint presentation by the cooperation Excellence United, which includes the exhibitors Glatt, Fette, Harro Höfliger and Uhlmann.