Certain containers used in life sciences, such as microtubes and small vials, can be difficult to manage on automated filling lines. Their shape often hinders them from standing securely on standard conveyors, which makes it harder to move them between machines during filling. At the same time, manufacturers handling high-value liquid drugs must maintain tight control over fill accuracy and reduce product loss at the end of each batch.
BellatRx developed the Constellation Monobloc to address these challenges. The servo-driven system performs pre-weighing, filling, post-weighing, capping, torque control, and inspection for containers commonly used in pharmaceutical packaging, including vials, microtubes, and cartridges. The system indexes unstable containers safely to prevent tipping or leaking during processing. Standard output reaches around 60 vials per minute, with higher speeds possible when dual robotic stations are installed.
Verifying Fill Volumes
Accurate dosing is a key requirement when working with pharmaceutical liquids. The system verifies each fill using a two-stage weighing process.
Before filling, the machine records the tare weight of every container. After product dispensing, the filled container is weighed again to obtain the gross weight. By subtracting the tare value, the system calculates the net fill amount.
This approach helps confirm fill accuracy and reduces the likelihood of underfilled containers during pharmaceutical packaging operations.
Handling Delicate Containers
Automated handling is achieved through robotic pick-and-place stations that transfer containers from trays into indexing pucks. These pucks guide the containers through filling, capping, and inspection and provide stability during processing.
Robotic grippers are sized to match the diameter of the vials to ensure careful handling. At the filling station, servo-driven pumps dispense precise liquid volumes while lifting nozzles help limit contact with the container opening and reduce aeration.
Closure Application and Inspection
Once filling is complete, containers move to servo-controlled capping stations. Rotation and downward movement are synchronized with the closure’s thread pitch, and torque sensors monitor the applied force to confirm proper sealing.
A vision system checks that caps are present and correctly positioned. If a container fails inspection due to fill weight or closure placement, it is automatically directed to a reject lane without stopping the machine. Finished containers are then placed back into trays by robotic arms.
Integration and Operational Features
The modular design of the Constellation Monobloc allows it to be integrated with additional downstream equipment. Labeling, laser marking, or cartoning systems can be added as part of a complete pharmaceutical packaging line.
The system can also accommodate different production needs. For example, units demonstrated at industry events have filled volumes below 1 mL, though larger fill ranges are possible depending on configuration.
Operational features are designed with usability in mind. Status lighting indicates machine conditions, and when operator intervention is required, the system illuminates the work area to improve visibility. The filling trolley can be removed without tools for cleaning, and a CIP cycle can flush wetted surfaces without disassembly.
Automation Trends in Pharmaceutical Packaging
Automation is increasingly used in pharmaceutical production environments. Processes that were once completed manually are now being automated to improve consistency and uptime.
Reducing manual handling can also help limit contamination risks and allow operators to load trays of containers rather than handling individual microtubes.
Learn More About Pharmaceutical Packaging Solutions
Systems designed for unstable containers help manufacturers maintain fill accuracy and improve process efficiency.
Learn more about BellatRx solutions for packaging for pharmaceutical and nutraceutical applications here.
