Telstar innovative developments for GMP Pharma aseptic production at CPHI

At CPHI (Barcelona, October 24-26, 2023), Telstar will be promoting the integrated developments for aseptic production lines and digitalization solutions in GMP environments and process automation, as well as the latest innovations developed by the company in both in line management devices and process analytical technology for pharmaceutical freeze-drying systems and aseptic manufacturing processes.

In the freeze-drying process field, the company will disclose, among other developments, Telstar Sublime, which has been selected as a finalist for the CPHI Pharma Awards 2023. It is an innovative system capable of monitoring the advance of the sublimation front in real time in GMP freeze-dryers. It is a single-use probe, containing 5 independent temperature sensors which are placed within the vial, including wireless communication, able to monitor the advance of the sublimation front accurately, key to optimize the primary drying steps in lyophilization processes.

In addition to this, Lyogistics Smart Format will also be promoted. It is a new system using a single mobile platform configured to automatically fit a wide range of vial sizes without the need to disrupt the isolated enclosure. There is no need for manual operations inside the aseptic area when changing formats, and no line clearance operations are required. Lyogistics Zero 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 will also be promoted alongside Lyogistics Smart R3 which is an automated inline vial management device able to reject, reintroduce and retrieve vials during loading / unloading process into pharmaceutical freeze-dryers, besides Lyonuc, a new nucleation induction method suitable for any type of freeze-dryer that reduces the primary drying cycle and ensures the uniformity and homogenization of all the vials in a batch.

During the event, the company will also boost the new Pharma 4.0 IoT Data platform for predictive and preventive maintenance. Telstar Insights collects and analyses in real time the operating data of the equipment to anticipate and avoid possible incidents during production. In addition of this, the latest next generation of engineering services for pharmaceutical production, designed to offer greater performance with less environmental impact from the initial design. Finally, the new solution in digitalization of pharma processes, DisQ (Digital Smart Qualification), will also be featured at CPHI. A new Digital Smart Qualification software for commissioning and qualification with digital documents to optimize the development lifecycle, risk management, validation, and verification processes.

Telstar is a leading global brand of aseptic process solutions. The company, part of the azbil Group, specializes in the development of highly complex projects, from integrated process equipment to design, engineering and construction of complete turnkey pharmaceutical and biotech production facilities, critical installations, clean rooms, and R&D laboratories.