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SYSTEM OVERVIEW:

This unused IMA SteriFill Smart Vial Filling Line (2023) is a multi‑head aseptic vial filling system designed for sterile pharmaceutical manufacturing. It processes 2R pre‑sterilized vials and stoppers using peristaltic pump technology and may be converted to other vial types with manufacturer parts. Designed for high-efficiency sterile fill-finish operations, this system integrates bag and tub/tray opening, robotic denesting, smart handling, vial loading, ALU capping, lyophilization integration, dual isolator/HVAC systems, and iFIX SCADA supervision into a single, advanced platform.

 

KEY CAPABILITIES:

• Multi‑head configuration (2 pumps) for parallel dosing.

• Peristaltic pumps for filling and transfer.

• Supports pre‑sterilized 2R vials and stoppers.

• Can be converted to other vial types with manufacturer parts.

• 100% in‑process checkweighing .

• Inline filling and stoppering.

 

PERFORMANCE:

• Throughput: Up to 7,100 vials/hour.

• Bag opening: 2 bags/minute.

• Tub/Tray opening: 2 tubs or trays/minute.

• Robotic de‑nesting: 2 tubs/trays per minute.

• Continuous‑motion rotary capping.

 

LYOPHILIZATION INTEGRATION:

• Minimax 2.8 Pilot Freeze Dryer with 5 shelves.

• Automatic stoppering pressure control.

• Integrated UPS.

• Miniloader CLU‑LM06 for automated loading/unloading.

• VHP sterilization for all isolators (with generator).

 

VISION & QUALITY CONTROL:

• Vision system for crimp quality with 3 cameras.

• Additional camera for cap‑side coding control.

• Dummy star wheels included for validation.

 

SCADA & AUTOMATION:

• GE iFIX supervisory SCADA system.

 

INCLUDED DELIVERABLES:

• Material certificates.

• Two years of spare parts.

• Startup parts for isolator.

• Stericap.

• SAT package.

• Validation package.

• Bag opening module.

• Tub/Tray de‑lidding system.

• SMART / MINIMAX / CLU integration.

 

WHY THIS SYSTEM:

• High throughput with 100% IPC.

• Deep automation to minimize contamination risk.

• Fully integrated filling, isolator, lyophilization, and capping flow.

• Comprehensive validation and documentation support.


BENEFITS:


  1. Its suitability for both medium and large batch sizes and large-scale production runs makes this solution ideal for small molecules, vaccines, biological therapies such as monoclonal antibody drugs and antibiotics. The line is divided into modules, each with its own isolator, configurable according to the production process and plant layout. Different isolators can be activated depending on the production goal, such as freeze dryer loading, liquid-only batch production or unloading and capping of freeze-dried products. Each isolator in the system can therefore be configured to manage different production phases and possibly optimise and parallelise production processes across different batches by leveraging the system flexibility.
  2. The design of the format-specific parts of the different machines enables format changeover time optimisation, while the installed IPC systems or the refill and restocking strategies minimise the number of rejects and maximise production efficiency.
  3. Thanks to the design flexibility of isolators and ventilation systems, high containment applications for high-risk, cytotoxic or biologically active products can be safely handled. VPHP decontamination can be used to ensure microbiological reduction at production start but also the final deactivation of biohazardous products, minimising risks for operators. Products with very stringent environmental control requirements can be managed – including cold (2-8°C) or hot (40-45°C) filled products, products highly sensitive to oxidants and others requiring a pure nitrogen atmosphere.



Note: Images taken during FAT testing at OEMs Site, The equipment is currently crated for immediate shipment and stored in Massachusetts.


This aseptic vial processing system is built for high-efficiency sterile fill-finish operations and combines bag and tub/tray opening, robotic denesting, smart handling, vial loading, ALU capping, lyophilization integration, dual isolator/HVAC systems, and iFIX SCADA supervision in one advanced platform.


Configured for high throughput with 100% IPC, this line is designed to support demanding sterile manufacturing environments where process control, consistency, and contamination reduction are critical. Its deep automation helps minimize contamination risk, while the fully integrated filling, isolator, lyophilization, and capping flow supports a streamlined approach to sterile vial processing. As offered by Surplus Solutions, this system also includes comprehensive validation and documentation support for installation, qualification, and regulatory readiness.


Included modules:


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