BIOKHIMIK JSC
Automatic line for washing, sterilization, filling and capping ampoules and vials with subsequent labeling for JSC “BIOKHIMIK" (Saransk)
JSC "BIOKHIMIK" (PROMOMED Group of Companies) is one of the leading industrial enterprises of the Republic of Mordovia and one of the most important manufacturers of medicines in Russia, founded in 1959.
As part of the company's development plan, a new site for the production of antibiotics in the form of lyophilizates was commissioned in 2020.
The main task was to find a modern combined line with the most compact overall dimensions for placement in an existing building built back in Soviet times.
The second task was the need to increase the capacity of the existing production and optimize the holding time of products in ampoules in open form after the lyophilization stage. Since the lyophilizate cannot be in the open for a long time, the main task was to increase the stability of the drug by reducing the holding time to the sealing stage.
To solve both problems, we have proposed a unique combined filling line in ampoules and vials produced by Rota Verpackungstechnik GmbH & Co. KG (Germany).
The rotary washing machine and the sterilization tunnel (in full compliance with the requirements of the European regulations for the production of medicines (GMP EU) are the most compact machines on the market and thanks to carefully selected equipment, we have successfully managed to place all the machines in existing confined spaces.
In addition, the filling machine was equipped with a special unit with a servo motor instead of a standard mechanical unit for accelerated sealing of ampoules. Thanks to additional stations (four stations instead of the standard two) we managed to increase the sealing speed from 6000 ampoules/hour to 12000 ampoules/hour, which significantly reduced the holding time to the seaming stage and solved the problem of lyophilization in ampoules.
Later, in 2022, the line was upgraded by installing an additional external washing machine connected to the seaming machine using a conveyor for automatic feeding of objects after the seaming stage.
This solution also allowed the Customer to provide washing, drying and decontamination of vials arriving after the lyophilization stage for highly active products.
The project is one of the very first projects carried out by our company, however, despite the complexity and complex of tasks, the project was completed on time, the equipment was put into operation and is successfully operated to this day.
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