Christine
Mayo

SURF Filling Vials, Not Filling Time: Design and Fabrication of a Mobile Vial-Filling Station for Pharmaceutical Freeze-Drying

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Christine Mayo

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Lyophilization, or freeze-drying, is a vital pharmaceutical manufacturing process used to stabilize compounds that exhibit heat sensitivity or a lack of stability in solution. As part of the ongoing advancement of lyophilization technologies, LyoHUB is a consortium of pharmaceutical companies with the goal of continuous improvement of lyophilization practices. LyoHUB has a Purdue University specialized laboratory used as a demonstration facility, primarily dedicated to advancing freeze-drying technologies. One of the key preparatory processes with daily characterization practices is filling vials with solutions to design lyophilization "cycles" complete with temperature and pressure profiles. In certain instances, the vial-filling process is required to adhere to aseptic standards, particularly with biologics. In the pharmaceutical industry, aseptic processes often utilize peristaltic pumps for automated dose delivery rather than the pilot-scale use of pipettes. To improve the efficiency of regular vial-filling within the LyoHUB laboratory, a mobile filling station has been designed to substitute manual pipetting with more precise delivery by a peristaltic pump. To answer the demands of an aseptic work environment and hasten the dose delivery process, the mobile filling station has been designed with doors that allow flexible access to operating with laminar flow and a glove box. The mobile filling station not only improves the cleanliness and time-efficiency within the hood but also creates a more organized laboratory by being mobile and eliminates the strain on research scientists that follows repetitive manual pipetting. Therefore, the mobile filling station increases safety and accuracy for the medicines and those working to produce them.

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Purdue University / 2023

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Christine Mayo

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