VarioSys: A modular construction system with a wide range of configurations

VarioSys: Ein sehr flexibles und zudem platz- und zeitsparendes System für die Kleinchargenproduktion. Mehrere Komponenten können, je nach Anforderung, als Produktionslinie aneinander gereiht werden. / VarioSys: A highly flexible and at the same time compact and time-saving system suitable for small-batch production. Several components can be linked in series to form a production line, as required.

Das Prinzip dieser neuen Lösung ist denkbar einfach in der Anwendung: In einem speziellen Isolator, der die Produktion unter Bedingungen der Reinraumklasse A ermöglicht, können einzelne Produktionsmodule nach dem lock-and-key-Prinzip eingebaut werden. / The underlying principle for this new solution is extremely simple in practice: A special isolator enabling production in cleanroom class A conditions can be equipped with individual production modules that fit on the lock-and-key principle.

Das neue Modul zur Verarbeitung von Ampullen. Die AFV 5105 verfügt übe zahlreiche Funktionen auf engstem Raum – und präsentiert sich dennoch sehr übersichtlich. / The new AFV 5105 module for processing ampoules offers a wide range of functions in a limited space – while maintaining a well-organized, functional appearance.

VarioSys features innovative technology for quick changing of machine modules within a production isolator. Bausch+Ströbel developed this production system in cooperation with Swiss isolator specialist SKAN. The system is suitable for a vast range of applications because a special isolator can be combined with various machine modules. Moreover, several modules can be linked in series with a sterilizing tunnel, cleaning machine or freeze-drier to form a production line.

Combining an isolator with machine modules specifically means that a production module can be moved out of the isolator just like a work bench and can be replaced by another module. A special inflatable gasket ensures that the isolator and production module are connected securely and hermetically sealed.

VarioSys in motion: VarioSys Move

Interchanging modules has been really straightforward already, but a new feature we have added facilitates the machine operators’ job even more:
Now, the modules can be interchanged automatically. VarioSys Move brings machine modules fully automatically from the parking position to the isolator and back again. The modules are precisely transported into the PSI-L isolator or into the parking position along an optical track. In the parking position, the transport system is recharged automatically.

At interpack, a full-scale model shows how exactly the system works: a B+S module for processing syringes in nests, SFM 5105, is interchanged fully automatically with a bag-filling module from Harro Höfliger, one of our Excellence United partners. Here, VarioSys Move transports the modules into the isolator fully automatically, following a programmed sequence. Alternatively, the modules can be controlled semi-automatically: an operator uses a remote control panel to bring the modules to the isolator – from there, they are transported into the isolator in a precise and fully automatic manner. One transport system can be used for several machine modules.

Benefits for the customers:

- Easy handling; no physical effort is required
- Precise positioning; no operator intervention is required
- The correct module is in the right place - guaranteed
- Machine modules can be navigated more easily (for safety reasons, the castors on the modules must not be designed to swivel).

At interpack we are presenting the Harro Höfliger module as well as the Bausch+Ströbel SFM 5105, a fully automatic intermittently operating machine for filling and closing of ready-to-use disposable syringes, vials or cartridges in nests and tubs. The machine operates at a maximum speed of 4,200 containers per hour.

New ampoule processing module presented at interpack

VarioSys is continually enhanced with the addition of new modules. In Düsseldorf, we are presenting a new machine module for processing ampoules. This module achieves up to 6,000 containers per hour at 100 percent IPC.

As with all VarioSys modules, our engineers had to master the challenge of fitting all functions into a narrow, confined space – but the functions still had to be well arranged and operator-friendly. They clearly met their mark with the new AFV 5105 machine module for processing ampoules. The two-head machine features a walking beam transport system, in which the ampoules are clearly visible, and is overall well arranged while offering a wide range of functions and operating at high speeds.

The machine version on display processes 6,000 ampoules per hour. It is possible to activate 100 percent IPC – without any speed reduction. The module can be fitted with any of our standard dosing systems, it has an automatic burner ignition device and can handle closed ampoules as well. Moreover, the ampoule tips are actively extracted from the machine. The dedicated extraction device can be set up inside the cleanroom, or in the technical area to save space.

Wide range of VarioSys machine modules

Further examples of VarioSys production modules are:

- a module which can accommodate table-top lab equipment or semi-automatic machines in individual configurations, as required.
- a fully automatic filling and closing machine (KSF 5105) or closing machine (KS 4105) for bottles or vials with a maximum speed of 3,600 containers/hour.

Utmost flexibility is achieved by the number of different dosing systems which can be provided, for example: peristaltic pumps or valveless rotary piston pumps for liquid products and auger dosing units for powder products. Single-use dosing systems can easily be fitted as well. The air flow pattern in the isolator can be adapted for safe processing of highly potent or toxic products.

VarioSys is a production system suitable for small batches that is very compact and time-saving, can be changed over quickly, can individually combine a wide range of components and can easily be adapted to changing needs by adding enhancements – while keeping investment costs low and qualification and validation periods short because the machines are standardized. This is a decisive advantage when under time constraints for the launching of new products.