adaptiQ™ system for ready-to-use pharmaceutical vials launched by SCHOTT

SCHOTT introduced its adaptiQ™ system for ready-to-use pharmaceutical vials, which allows for more flexible manufacturing concepts and more efficient filling. Designed in close collaboration with filling line manufacturers to meet the pharmaceutical industry’s process requirements, SCHOTT adaptiQ consists of a patented nest that securely holds as many as 100 clean and sterile vials in an industry standard tub. The pharmaceutical company can then immediately fill these vials on its filling lines without having to perform arduous processing steps like washing, drying, and sterilization. The adaptiQ system is on display at the American Association of Pharmaceutical Scientists (AAPS) Annual Meeting and Exposition in San Antonio, Texas on November 11 to 14, 2013 at booth #4209.

With adaptiQ, SCHOTT unveiled a new concept of ready-to-use pharmaceutical vials that allows for vials to be subjected to all of the processing steps while inside the nest.

Pharmaceutical companies are showing greater interest in flexible manufacturing concepts that allow them to produce in small batches with different packaging configurations for more efficient filling. Unlike other solutions currently on the market, adaptiQ subjects vials to the processing steps—including freeze-drying—while inside its patented nest design. Besides simplifying the process, the nested packaging protects the glass containers from scratches caused by vial-to-vial and vial-to-machine contact. This not only reduces the reject rate, but preserves the cosmetic quality of these packaging products.

“By shortening the process chain and reducing its complexity, we can lower costs for pharmaceutical companies. They’ll no longer have to invest in clean rooms, special washing machines, and sterilization tunnels, or spend money to operate them. This is exactly what adaptiQ achieves,” said Gerry Wilkins, Director of Sales for SCHOTT North America. “Moreover, if pharmaceutical companies can use the same production line for various lot sizes and different types of containers like syringes, vials, and cartridges, this gives them greater freedom to quickly react to new market demands.”

Patented nest design

Pharmaceutical companies have taken advantage of nested packaging designs in other areas of packaging for years. Roughly 80 percent of all prefilled syringes sold in the world today are delivered to the filling lines in the form of a nest and tub configuration. Attempts to apply this successful syringe approach to other types of containers have failed in the past because vials still had to be individually removed from the nest for certain processing steps.

adaptiQ is based on a patented new nest design that now offers a solution to this problem. The vials are held by the neck and can be lifted out of the nest individually while avoiding glass-to-glass contact. Furthermore, the bottom is freely accessible and thus ensures the perfect temperature transition, especially during lyophilization. The patented design developed by SCHOTT follows the common format of syringe manufacturing to ensure that adaptiQ can be processed on existing nest filling lines.

Market introduction is scheduled for the third quarter of 2014 and will start with the most popular ISO formats 2R and 4R. SCHOTT will gradually introduce adaptiQ in all of the most common ISO formats ranging from 2R to 30R. Initial samples are now available.

About SCHOTT

SCHOTT is an international technology group with more than 125 years of experience in the areas of specialty glasses and materials and advanced technologies. SCHOTT ranks number one in the world with many of its products. Its core markets are the household appliance, pharmaceuticals, electronics, optics, transportation and architecture industries. The company is strongly committed to contributing to its customers’ success and making SCHOTT an important part of people’s lives with high-quality products and intelligent solutions. SCHOTT is committed to managing its business in a sustainable manner and supporting its employees, society and the environment. The SCHOTT Group maintains close proximity to its customers with manufacturing and sales units in all major markets. Its workforce of around 16,000 employees generated worldwide sales of $2.6 billion (approximately 2.0 billion euros) for the 2011/2012 fiscal year.