Bench-Top Vial Sealing Machine

Semi-Automatic Vial Sealing for Small Batch Processing

AST's Vial Sealing System (VSS) is a bench top, a semi-automatic machine used for sealing or capping of pharmaceutical vials and bottles with aluminum caps.  The Vial Sealing System is ideal for development, pre-clinical, clinical, pilot and compounding pharmacy applications.  The VSS provides complete and precise control of the container sealing or capping operations to ensure the highest quality vial seal. 

Vial Sealing System Advantages

The Vial Sealing System is easily operated using an intuitive, high-resolution touchscreen to create to control and monitor the sealing process.  The sealing head assembly has sensitive closed loop feedback to accurately control the compression of the vial stopper and cap combination to the defined setting established by the operator.  By tightly controlling the compressive force being applied during the sealing process, the Vial Sealing System reduces stopper compression variability and produce consistent seals.

To form the aluminum skirt on the cap around the neck of the vial the VSS rotates the vials and once the speed setting is attained a free spinning disk gently rolling the skirt against the neck of the vial.  This process generates few particles and provides a pharmaceutically aesthetic seal without witness marks common with jaw style crimping mechanisms.

The system's compact design and materials of construction make placement within commercially available isolators, bio-safety cabinets or laminar flow hoods (LAFs) simple.  The system's versatility, features, and compact size makes it ideally suited for labs and cGMP environments for small batch pharmaceutical capping applications.

Applications include:

  • R&D, preclinical and process development
  • Clinical trial materials manufacturing
  • Pilot scale cGMP manufacturing
  • Personalized medicine
  • Compounding pharmacies
  • Stability studies

Benefits

  • Consistent, high quality vial seal
  • Ability to process a wide range of vials and vial finishes
  • Automatic sealing head adjustment
  • Simple format change-over
  • Programmable compression force & crimping speed
  • Closed loop feedback for compression force improves Container Closure Integrity (CCI)
  • Sealing process generates few particles
  • Compact system footprint allows for placement with an isolator, biological safety cabinet or LAF

AST’s Vial Sealing System (VSS) is a bench top system for semi-automated capping or sealing of pharmaceutical vials and bottles.  The system is specifically designed to meet the unique challenges of small batch lab and cGMP applications.  The system’s versatility allows processing a wide range of vial or bottle sizes and finishes.

To ensure complete enclosure and thus the sterile integrity and stability of drug product within a vial, several key process parameters need to be carefully maintained when capping or sealing a vial.  The most critical is maintaining the proper amount of stopper compression during and after the sealing process.  The Vial Sealing System provides complete control and automates these critical process variables to produce a repeatable, high quality seal.

The vials or bottles are manually placed on the machine by the operator.  Once placed, the sealing process is initiated and the sealing head moves down to compress the vial stopper until the closed loop compression force feedback confirms the operator programmed compression setting is achieved.  With the stopper compressed the vial is rotated and the free spinning disk gently forms the aluminum skirt of the cap around the neck of the vial.  This sealing process maintains the compression of the rubber stopper, generates fewer particles and provides a pharmaceutically aesthetic seal without the witness marks common to jaw style crimpers.

The aseptic and compact design of the machine makes it well suited for aseptic environments provided by isolators, biological safety cabinets or laminar air flow (LAF) hoods.  The system is compatible with hydrogen peroxide isolator bio-decontamination, and can be manually cleaned using common reagents like isopropyl alcohol and sporicides.

Changing the system to process different containers is easy, and can be done in minutes without tools by changing only a few parts.

Coming Soon

Technical Information

Dimensions (LxWxH)

725mm x 500mm x 630mm

Containers:

Vials & Bottles

Vial Finish:

13mm, 20mm, 32mm

Vials Sizes (Dia./Height):

Ø16mm-47mm / 35mm-100mm

Aluminum Seal / Cap Type:

DIN standard with or without flip-top

Sealing Method:

Spinning roller

Production Rate:

Up to 15 cycles per minute

Electrical Utilities:

110/220VAC – 60/50Hz.

Air Supply:

Clean dry air 7 bar, 0.5L/min free air

Materials of Construction:

Pharmaceutical grade stainless steels and plastics

Coming Soon

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