Same Footprint, More Productivity: Designing a Vial Filling Line in Saudi Arabia

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True Line Competence

The new powder filling line includes an RRN 2053 washing machine and an HQL 3480 sterilization tunnel to clean, sterilize and depyrogenize the containers. The heart of the line is an AFG 3020 powder filling machine, which operates according to the vacuum compressed air principle. It fills the powders into sterile injection vials with the highest precision without any dust.

After the vials are closed with rubber stoppers, the VRK 2005 capping machine makes sure that they are reliably sealed. Apart from these line components, Bosch also provided a complete solution for the generation, storage and distribution of WFI and pure steam. WFI is used in the washing machine, as well as for cleaning of certain format parts.

In addition, the company supplied the factory with an autoclave. It is used to sterilize format parts of the filling machine in order to prevent contamination. The WFI generation unit type 250-S4 produces the steam required for the autoclave. Thanks to its special design, it is able to produce either WFI or pure steam, or both simultaneously, depending on the production requirements.

Vial Inspection Ensures Product Quality

After filling, the vials are inspected for container and product integrity, and labelled before they are ready for secondary packaging. The whole production line can be monitored from a centrally located office, where all process parameters are displayed on a single screen. This gives the plant manager a detailed overview of the filling process at all times, as well as the possibility to control all steps carefully.

One of the biggest challenges Bosch faced when developing the project plan was to keep production downtime to a minimum. The regular production processes of Tabuk Pharmaceuticals had to be affected as little as possible. “Since the experts provided a very detailed schedule, we were able to controlall steps precisely, including the plans for the required cleanroom technology. This made the switch to the new line as smooth as possible,” Dr. Hussein says.

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