Biopharmaceutical drugs such as mRNA vaccines against COVID-19 differ from traditional pharmaceuticals not only in their production processes. They are also extremely sensitive and only have a very short shelf life in liquid form. Freeze-drying is often the only way to preserve these active ingredients for longer than a few days. However, the interfaces between filling and freeze-drying pose major challenges for personal and product protection.

Here, the new, patented loading system for freeze dryers from the Syntegon product brand SBM (Schoeller Bleckmann Medizintechnik) ensures maximum process reliability - and considerable space savings at the same time. Thanks to its new front pusher design, the system loads vials into the freeze dryer using a linear pushing and pulling movement of the push arm. Unlike other systems, the innovative scissor drive is not moved by a hydraulic push rod, but by a mechanical servo drive.

The patented solution offers several advantages: Firstly, the articulated arms and the push arm are so compact that the loading system can be installed within the isolator dimensions, saving manufacturers a lot of space in the fill-finish area. All components of the loading system are easily accessible with gloved hands and are easy to clean, sterilize and maintain.

The drive unit of the loading system is located below the carrier platform and therefore outside the process area. This enables repairs and maintenance of the drive unit without compromising the sterility of the isolator above the carrier platform. At the same time, operators and maintenance technicians are protected from highly toxic products. Thanks to the innovative front pusher solution, the bellows required for a hydraulically operated push rod is no longer necessary, making the system easy to clean. Furthermore, there is no risk of possible contamination of the product with any escaping hydraulic fluid.