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Processing of pre-sterilised objects

Ready-to-use primary packaging

Processing of pre-sterilised objects

Ready-to-use (RTU) primary packaging materials are pre-manufactured, cleaned and sterile packaging components that can be used directly in pharmaceutical filling.

Ready-to-use (RTU) primary packaging materials are pre-manufactured, cleaned and sterile packaging components that can be used directly in pharmaceutical filling. These include vials, syringes or cartridges that have already undergone validated washing, depyrogenation and sterilisation processes and are delivered in suitable packaging systems such as tubs or trays.

The use of RTU objects makes it possible to dispense with complex and cost-intensive in-house process steps. As a result, production lines can be significantly simplified, throughput times shortened and the risk of contamination significantly reduced. At the same time, manufacturers benefit from greater process reliability and reproducible quality standards.

RTU primary packaging offers decisive advantages, particularly in aseptic production and for smaller batch sizes, clinical production or frequent product changes. They support flexible, modular system concepts and help to fulfil time-to-market requirements efficiently. This makes them a central component of modern, sterile production strategies.

Processing of RTU primary packaging in a nest or tray

RTU primary packaging in nests

RTU primary packaging in nests

The pre-sterilised primary packaging materials such as syringes, vials or cartridges are securely fixed in the nest. They enable precise, automated processing in filling lines, minimise particle risks and reduce cleaning requirements and validation steps in pharmaceutical production.

RTU primary packaging in trays

RTU primary packaging in trays

Ready-to-use vials in trays are fed directly into the filling line without prior washing and sterilisation steps. Automated removal and transport systems enable efficient sorting and precise positioning. This reduces process times, minimises contamination risks and increases flexibility for medium to high production volumes.

Safe and efficient processing of RTU primary packaging materials

We process ready-to-use syringes, vials and cartridges in nests as well as in trays – flexibly, safely and tailored to different production requirements. Our systems enable gentle, precise handling of the objects and ensure stable processes across the entire line. Whether small batches in nests or larger batch sizes in trays: we offer suitable solutions for reliable, efficient and aseptic processing. Thanks to modular concepts, our systems can be optimally integrated into existing production environments and support a consistently reproducible process.

RTU platforms

Our solutions for flexible processing of RTU packaging materials

CombiSys

System solution with efficiency and performance.

CombiSys

CombiSys is an ideal solution for CDMOs and pharmaceutical manufacturers who require a high degree of flexibility and for whom the scalability of the machines used is a competitive differentiator. With this solution, different packaging materials can be processed on a single platform – with an output of up to 30,000 objects per hour and 100 % in-process control (IPC).

CombiSys
VarioSys

Innovative. Flexible. Efficient.

VarioSys

The innovative and highly flexible VarioSys® production system for biotechnological products and pharmaceuticals essentially consists of two components: an isolator system from SKAN and customised machine modules from Bausch+Ströbel. The system is designed in such a way that the production is made extremely flexible by exchanging modules.

VarioSys
GENEX

Gloveless filling machine.

GENEX

GENEX is the latest in fully integrated automation. Precision automation can demonstrably lead to better and safer results than relying on human intervention. GENEX therefore enables efficient production while maximising process and production reliability.

GENEX
A safe route from the process to the patient

Integrated solutions

A safe route from the process to the patient

True production reliability builds trust, quality, and sustainable success. It arises from the coordinated interaction of people, machines, and processes – not from isolated technologies.

Discover the advantages of integrated solutions

Requirements and solutions

Annex 1 at a glance: What it means and our solutions

As a solution provider of high-quality filling systems, we develop technologies that are specifically designed to meet these requirements. With intelligent automation, sophisticated design and technical precision, we combine regulatory safety with economic efficiency.

Annex 1 at a glanceAnnex 1: Our solutions
Annex 1 at a glance: What it means and our solutions

Service & Support

LifeCycle Services for maximum system performance

With our LifeCycle Services, we accompany you through every phase of your pharmaceutical production - for maximum system performance, optimum availability and sustainable success over the entire life cycle.

Get to know our services
LifeCycle Services for maximum system performance

Do you have any questions?

Let's work together to move your project forward.

Our experts are always at your disposal and look forward to getting to know your specifications. Get in touch with us - we will advise you personally and find the right solutions for your requirements.

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Let's work together to move your project forward.