Breakthrough solutions for pharmaceutical manufacturing

With more than 50 years’ experience, Telstar has become a leading global brand of aseptic process solutions. In recent years the company has reinforced the development of new process equipment & integrated solutions in isolation technology systems, sterilization and freeze-drying applications covering the complete phases of a pharmaceutical manufacturing process.

In the context of Pharma 4.0 transformation, Telstar has also played an active role in the development of innovative smart developments in the process analytical technology field & integrated process equipment and laboratory integrated management systems.

Here are some examples of these technologies. In the freeze-drying process field, Lyogistics Zero is the only automatic vial loading & unloading system for freeze-drying processes which can be cleaned (CIP) and sterilized (SIP) in place, inside the freeze-dryer chamber. Lyonuc® is the nucleation induction method developed by Telstar, suitable for any type of freeze-dryer that reduces the duration of the primary drying cycle and ensures the uniformity and homogenization of the vials in all the batches, respecting the product’s morphology and physiochemical properties. Lyogistics Smart R3 is the new automated inline vial management device able to reject, reintroduce and retrieve vials during the loading / unloading process into pharmaceutical freeze-dryers.

Telstar Lyosensing is a versatile process analyzer developed to monitor the freeze-drying cycle & detect and prevent real and virtual leakages in pharma freeze-dryers. Telstar Lyometrics is an innovative soft-sensor temperature monitoring system in GMP industrial freeze-dryers with automatic loading/unloading systems designed to provide on-line monitoring of the global batch product temperature during primary drying, without the limitations and interferences imposed by physical probes. Lyomega SV is a new single-vessel GMP production freeze-dryer, optimized to maintain conventional work space while making the footprint up to 20% smaller than a lyophilizer with standard external condenser configuration. Telstar Arctic is the basis of a new generation of environmentally friendly refrigeration systems that operate with natural gases. This is a comprehensive project to develop natural gases cooling systems that the company will eventually be implementing to the whole range of freeze dryers. As a sample, LyoQuest Arctic is the first laboratory freeze dryer operating with natural gases. Unlike conventional freeze dryers using HFC cooling gases, this innovative bench-top lab freeze dryer reduces the GWP impact more than 1,000-fold.

Telstar Sterimega Plus is a new compact steam sterilizing autoclave with GMP design, including hinged front-facing access panels which open completely to provide full access to the technical area of the equipment. A new automated product handling system for automatic loading and unloading processes integrated in high-capacity pharmaceutical sterilization systems. Designed primarily for terminal sterilization processes in autoclaves with a capacity of over 50 m3, the new robotized solution is incorporated in the counter-pressure autoclave Telstar SteriDelta series. The system is engineered to cover whole operational phases, connecting the sterilization process from the filling line to the inspection line.

Telstar has developed a new smart HVAC control system for clean rooms, whose monitoring and controlling capability allows the system to reduce the frequency of air renovation cycles and to reach the maximum level permitted of particles in the room in accordance with GMP classification, while saving over 40% in energy consumption depending on the room operation and use.

The latest sterility test isolators integrated with Telstar’s innovativeionHP+ bio-decontamination system, proven to dramatically decrease cycle times, increase time available for process and reduce running costs, as well as other innovative solutions in isolation technology systems, sterilization and water & pure steam generation.