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Automated Production Line for the Filling and Crimping of Vials

Custom Automation - Case Study

    Nova Laboratories: A Leader in Aseptic Processing

    Our client, Nova Laboratories, is a leading CDMO based in Leicestershire, UK, specialising in the aseptic processing of pharmaceutical, biopharmaceutical, and medical device products.

    The Project

    As a trusted partner, 3P innovation had previously designed and manufactured fill-finish lines for Nova Laboratories, which are now successfully installed and operational at their Leicester site.

    For this latest project, the client required a solution to accommodate a smaller vial while also increasing throughput capacity. This system needed independent filling and crimping machines, separated by a physical barrier to meet Annex 1 requirements. The fill and crimp chambers required automatic vial transfer and needed to fit within the tight spatial constraints of their isolator.

    Additionally, Nova Laboratories required a specialised system to integrate with their novel pick-place invert mechanism for the feeding of bulk pre-sterilised vials, a departure from conventional fill-finish lines.

    A Collaborative Approach to Innovation

    This project was a true collaboration, with engineers from both Nova Laboratories and 3P working closely to develop a solution. By leveraging our expertise in automation and precision engineering, we delivered a system that seamlessly integrated into Nova’s operations, while maintaining the highest standards of aseptic processing.

    Smart Engineering

    Honeycomb Tray-3

    Honeycomb tray design

    Developed in partnership with Nova Laboratories, this innovative tray prevents glass-on-glass contact of the pre-sterilised vials, eliminating the risk of vials toppling, thereby ensuring safe handling throughout the process.

    DSCF5441

    Compact lift-lower-rotate modules

    Utilising advanced ball - screw spline technology, this system enables high-speed and precise transfer of the vials, stoppers and caps, while optimising space efficiently within Nova’s facility.

    DSCF5515

    Precision transport system

    A walking beam style transport enables linear vial movement using only rotary motion through seals, ensuring sterility is maintained at every stage and providing delicate handling of the glass vials.

    DSCF5486

    Ergonomic guarding design

    Prioritising operator safety and comfort, the system features intuitive guarding that facilitates easy access.

    Why Nova Laboratories chose 3P innovation

    Having successfully partnered with Nova on multiple projects, 3P innovation was the clear choice for this challenge. Our ability to design and deliver highly innovative, custom solutions - while working within complex space and regulatory constraints - set us apart. Our understanding of Nova’s needs, combined with our expertise in aseptic automation, ensured a solution that not only met but exceeded expectations.

    Together, Nova Laboratories and 3P innovation have once again pushed the boundaries of pharmaceutical manufacturing, reinforcing Nova’s position as a leader in aseptic processing.

    Testimonial

    "Working with 3P innovation has been a great experience. Their engineering expertise has been instrumental in transforming our vial filling and crimping process, helping us increase throughput while maintaining strict aseptic standards. The team was highly collaborative and knowledgeable, making the entire project smooth from start to finish." Sam Green, Equipment Projects Manager at Nova Laboratories

    Discover our Fill-Finish Techology

    F2V transparent-1

    Liquid Fill-Finish Technology

    F2VMKII - F2W.18.2-1

    Gravimetric Powder Filling Technology

    Crimper_PNG (most up-to-date)

    Rotary Crimping Technology