Intelligent vial rejection module for automatic vial loading/unloading systems


Compact IVRM from Telstar improves freeze-drying processes and automates quality control procedures

The intelligent vial rejection module (IVRM) is an inline manipulation system that has been designed to detect and treat vials during freeze-drying. Developed by Telstar, it is a compact, inline quality control unit that can be fully integrated into automatic loading/unloading systems to automatically manage the paths of vials during the loading and/or unloading of freeze dryers.

The IVRM has been designed to provide two main functions: the detection and subsequent management of a specific vial in the process line. The module is able to identify and separate a specific vial according to different parameters (stopper position, missing stopper, colour variation, etc.) and, after identification, it is capable of performing several tasks: rejecting the vial, isolating it for sampling or for a specific function, introducing a pre-prepared vial or re-introducing a vial following removal.

The innovative IVRM represents a compact and versatile solution for inline vial management at high speeds, ensuring appropriate processing of lyophilised products as well as reducing the risk of batch contamination, spoilage and operator intervention.

Telstar has developed a new generation of vial loading and unloading systems that can be integrated into freeze dryers and offer greater robustness, efficiency, reliability and accuracy in the vial transport and transfer process, in addition to easier cleaning and simplified maintenance.

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The improvements offer increased vial transport security during loading and unloading, preventing breakage and significantly reducing the number of rejects. The improvements include new vial descrambling modules that are suitable for unloading speeds of up to 400 vials per minute with a typical rejection rate of 0.01%. Telstar has also introduced an ultra-compact loading mechanism that results in a 40% reduction in the space required in the cleanroom.