Telstar offers new-generation vial loading and unloading systems


Suitable for unloading processes operating at up to 400 vials a minute

Telstar has developed a new generation of vial loading and unloading systems that can be integrated into freeze dryers.

The Barcelona, Spain-based supplier of aseptic systems says the new equipment offers greater robustness, efficiency, reliability and accuracy in the vial transport and transfer process, as well as easier cleaning and simplified maintenance.

The improvements are mainly concentrated in the transport conveyor transition modules and the vial alignment systems, which offer increased security of vial transport in loading and unloading processes, resulting in elimination of breakage and significant reduction in rejects.

Telstar has developed a pusher-type loading mechanism with a 40% shorter length than conventional systems, which reduces the footprint required in the aseptic area and increases the size range of shelves which can be automatically loaded.

The new design also features a built-in HMI screen that offers improved ergonomics and cleaner construction compared with screens supported on floating columns. Due to its compact and robust design, the mechanism can be integrated with freeze drying equipment with shelf widths of up to 1500mm, thereby increasing the loading capacity per row by 25% over earlier designs.

The company has also developed and tested longitudinal transitions, sliding longitudinal transitions, active and passive 90° rotations, transitions with curved belts, with T-shaped belts and other various other geometrical arrangements required to accommodate the configuration of loading systems. By combining modules, the transport system can be readily configured to any layout.

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A vial single-lining system accepts vials unloaded from the freeze dryer in random packets and aligns them at high-speed so that they can be transferred in a single line towards the capping machine. It is suitable for unloading processes at up to 400 per minute with a typical rejection rate of 0.01%.