Building Flexibility into Aseptic Processing
Project Overview
GBA transformed an outdated, non-compliant packaging suite into a state-of-the-art aseptic filling suite within a 700,000 SF multiproduct facility. To meet the highest standards of aseptic processing, a dedicated aseptic core was created, isolating the new suite from the rest of the facility to eliminate the risk of mix-ups or cross-contamination. The redesigned suite features a new filler with a washer and tunnel, dedicated equipment and component prep areas, and significant upgrades to the facility’s electrical, mechanical, fire protection, and communication systems.
Key Equipment & Capabilities
- Cartridge/Carpuject Filler (Bosch Syntegon) – 300 units per minute
- Support Equipment – Passive RABs, washer, tunnel, filler
- Single-Use Technology –Needles and tubing for optimized dosing and confidence to manage dozens of product fills
- Precision Filling – Partistatic filling line pumps
- Sterilization & Preparation – 2 part washers, 4 autoclaves
- SPA Equipment Preparation Areas – Supporting aseptic workflow
- Additional Components: Advanced aseptic assembly components on the line
Enhancing Versatility & Efficiency
The new filling line is designed for versatility and can handle a range of products, including multiple cartridge and Carpuject formats. Incorporating single-use technology, the line enables quick turnaround times and requires fewer changeover parts, enhancing efficiency and minimizing downtime.
Mezzanine Addition & Facility Optimization
A new mezzanine was constructed in the center of the operational facility to house five custom air-handling units. This addition optimized airflow and provided essential access for construction, all while maintaining the facility’s full operational capacity.
Seamless Integration & Regulatory Compliance
GBA’s careful planning and expertise in highly regulated environments ensured the renovation met the strictest industry standards for safety and performance. The result is a fully integrated, efficient aseptic filling suite that boosts production capabilities while maintaining compliance with regulatory requirements and ensuring uninterrupted operations.