Telstar launches Lyogistics Smart R3: New automated inline vial management device able to reject, reintroduce and retrieve vials during loading / unloading process into pharmaceutical freeze-dryers

The purpose of the innovative inline vial management device developed by Telstar is to reject, retrieve for sampling, or reintroduce vials automatically during loading / unloading process into pharmaceutical freeze-dryers. Under the brand of Lyogistics Smart R3, the new system has been designed for automatic detection & treatment of vials in an automatic line.

The new compact inline quality control unit needs to be fully integrated in automatic loading & unloading systems in order to automatically manage the paths of vials during the loading and/or the unloading of freeze dryers. Designed for detection and the subsequent management of a particular vial in the process line, the module is able to identify and separate a specific vial according to different parameters: stopper position, missing stopper, wrong stopper position, color variation, etc. After identification, it is capable of performing several tasks: rejection of the vial to a rejection container, separation of vial for sampling, separation of one vial for a specific function, introduction of a pre-prepared vial or re-introduction of a vial subsequent to removal.

The system integrates several mechanisms ensuring appropriate processing of lyophilized products as well as reducing the risk of batch contamination, spoilage and the time of operator intervention. Vials are transported by conveyors and screws without pushers, neither bellows nor mechanisms in contact with product, which allows the module to work in an open system without concealed parts guaranteeing cleanliness and greater performance. In addition, the compact module is featured by a diaphanous nature, unobstructed and clear. No racks, belts, or linkages occupy the work area and all mechanisms are under the base plate or closed. The compact and versatile solution, which has been conceived for management at high process speeds of up to 600 vials per minute, is compatible with cold sterilization methods as Hydrogen Peroxide and offers easy integration with RABS and isolators.

The versatile module has been configured to be integrated to industrial-scale single-side or pass-through freeze-dryers and the vial detection/sampling system will work according to the freeze-dryers features, only inlet side, inlet and outlet side (same side) and inlet and oultlet side (opposite side).

Lyogistics Smart R3, in which the three main functions (rejecting, reintroducing & retrieving) are behind the naming concept, is a result of Telstar’s continuous innovation process. In fact, this version enhances the unit presented by the company in 2015 doubling the maximum speed of vials and reducing the footprint, as well as the amount of change parts when different vial formats need to be used.