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The isolator encloses the critical sterile sections of a filling line and separates the product from direct operator intervention.
A typical process can include:
Sterile Container Entry → Filling → Stoppering → Capping / Sealing → Inspection → Sterile Exit
The isolator maintains controlled airflow and environmental conditions around these processes while supporting glove access, material transfer and automated production-line operation.
Parameter | Specification |
Equipment Type | Pharmaceutical Aseptic Filling Line Isolator |
Critical Zone | Class A |
Typical Lines | Vial / PFS / Cartridge / RTU / Sterile Filling |
Exterior Material | 304 Stainless Steel |
Critical-Zone Material | 316L Stainless Steel |
Bio-Decontamination | VHPS / H₂O₂ |
Control System | Siemens PLC + IPC |
Temperature / Humidity Control | Independent Control Available |
Environmental Monitoring | Integrated / Continuous |
Material Transfer | Multiple Sterile Transfer Options |
Glove Leak Testing | Wired / Wireless Optional |
MOCK-UP Service | Supported |
FAT / SAT | Supported |
CDCV / Validation Support | Available |
Customization | Full Line Integration |
For sterile liquid or powder filling, stoppering and capping processes.
For RTU syringe filling and closing under isolated conditions.
For sterile cartridge filling, stoppering and capping.
For ready-to-use vial, syringe and cartridge production.
The enclosure length, glove access, monitoring points and transfer interfaces can be customized according to the equipment layout.
MAYA supports complete filling-line isolator projects with:
Process consultation
MOCK-UP verification
2D / 3D engineering
Filling-line integration
FAT / SAT
Sterilization cycle development
Validation support
Installation and commissioning
Operator training
Long-term technical service
The timeline varies based on the complexity of the integration and specific line requirements. Generally, following initial technical consultations and 3D modeling approvals, manufacturing and comprehensive in-house testing require a dedicated schedule. We prioritize precise engineering over rushed assembly, ensuring every unit passes rigorous Factory Acceptance Testing (FAT) before shipment.
The integrated Siemens PLC+IPC control system features multi-level access control designed to comply strictly with FDA 21 CFR part 11. This ensures that only authorized personnel can alter critical parameters such as H2O2 concentration or differential pressure, thereby maintaining data integrity, preventing accidental process deviations, and providing a clear audit trail for regulatory inspections.
Our Cycle Development and Cycle Validation (CDCV) service is a comprehensive support package. We do not just deliver the hardware; our experts conduct extensive validation studies to establish the most effective and repeatable H2O2 sterilization cycle for your specific load and configuration. This ensures you achieve the required 6lg reduction consistently while optimizing turnaround times between batches.
We provide complete life cycle support. This extends from the initial installation scheme design and Site Acceptance Testing (SAT) to long-term maintenance guidance. Our global experience allows us to offer prompt technical assistance, spare parts availability, and ongoing compliance consulting to keep your isolation system operating at peak performance year after year.