No more breakage with latest vial loading and unloading systems

Telstar has introduced a new generation of vial loading and unloading systems that can be integrated into freeze dryers and that offer greater robustness, efficiency, reliability and accuracy in the vial transport and transfer process, in addition to easier cleaning and simplified maintenance. The improvements are mainly concentrated in the transport conveyor transition modules and the vial alignment systems, which offer increased security of vial transport in loading and unloading processes, resulting in elimination of breakage and significant reduction in rejects. Telstar has also developed a pusher-type loading mechanism with a 40% shorter length than conventional systems, which reduces the footprint required in the aseptic area and increases the size range of shelves that can be automatically loaded.

A standard range of modules that combine easy installation and accurate alignment between conveyor systems, ensuring that the vials move smoothly and continuously between the modules and makes the vial transition process more robust and reliable. Designed to be applied to any vial loading system, this system provides greater efficiency in the transition process and reduces vial losses during transport owing to breakages or falls.

Telstar has developed and tested longitudinal transitions, sliding longitudinal transitions, active and passive 90˚rotations, transitions with curved belts and T-shaped belts and various other geometrical arrangements required to accommodate the configuration of loading systems. By combining modules, the transport system can be readily configured to any layout.

The vial single-lining system is a complex element for accepting vials unloaded from the freeze dryer in random packets and aligning them at high-speed so that they can be transferred in a single line towards the capping machine. Since there are many applications that involve unloading vials onto a rotary accumulation module, Telstar has developed an alternative based on different single-liner system configurations that enable unloading the shelves of the freeze dryer while preserving as much as possible the row order followed during the loading process.

The new Telstar vial descrambling modules are suitable for unloading processes at up to 400 per minute with a typical rejection rate of 0.01%. Telstar has come up with a range of single-liner modules to address the various speed and layout requirements of specific clients.

The loading mechanism with a 40% shorter length than conventional systems is primarily intended for installation in freeze dryers which, owing to cleanroom space constraints, need to have a fixed loading system with a compact footprint. The new design also features a built-in HMI screen that offers improved ergonomics and cleaner construction compared with screens supported on floating columns. Owing to its compact and robust makeup, the mechanism can be integrated with freeze drying equipment that has shelf widths of up to 1500 mm, thereby increasing the loading capacity per row by 25% over earlier designs.

Telstar, www.telstar.com.