"Our Battle in a Bottle": Marchesini Group's solutions for vaccine packaging

Science, research and community: everyone must play their part in the global fight against Covid-19 and this is the reason we decided to bring our technologies for the whole vaccine packaging process, from beginning to finish, to this edition of CPHI Discover.

In recent months we have achieved extraordinary results thanks to technology, but also to the endeavours of the various divisions of the Group involved in the production stage. Our goal is to produce high-level performance, efficient and reliable machines and lines, shortening delivery time.

We have already received several requests for vaccine packaging solutions from various countries around the world: in Europe in particular for the UK and Italian markets, but also in the United States, in China and even in Indonesia, where we have recently converted an existing line into a Covid-19 vaccine production. And that is not all. Projects in Latin America are also in the process of being implemented, with the shipping of CMP Phar.ma machines to a Mexican customer who will involve them in the packaging process for the Astra Zeneca vaccine. Finally, a major Russian biotechnology company, Biocad of Saint Petersburg, is today using a Marchesini Group line to produce the Sputnik V vaccine at a rate of 100 vials per minute.

Focus on the Marchesini Group line for the packaging of the Russian Sputnik V vaccine

The project dates back to 2018, when Russian company Biocad enlisted Marchesini Group to design a line for the filling and packaging of their own Biotech products. To further protect the filling and capping machines from any risk of external contamination, containment cabinets isolate the environment where the product is exposed from the environment where the operator is present. When the pandemic hit, Biocad decided to use the machines for Sputnik V, adapting the existing line to its new production needs.

The line delivered to the Russian costumer is composed of a machine for washing vials, a vial sterilisation and depyrogenation tunnel, a filling machine which also fits a rubber stopper, and a capping machine for vial closure with an aluminium sealing ring. To guarantee precision dosing, the filling machine is equipped with an “in-process control” system which checks the weight of 100% of vials, both when empty and immediately after filling.

All the Marchesini Group solutions for vaccine packaging in vials and syringes

Marchesini Group can provide numerous solutions for the filling and primary and secondary packaging of vaccines in vials and in syringes. Concerning the solutions in vials, the rotary continuous motion machines of the WR family carry out internal washing and drying of SVP (Small Volume Parenteral) vials, which then travel through a depyrogenation tunnel. Next, the STERY-LA/LC filling and capping machines for liquid or freeze-dried products ensure aseptic filling with total or partial closing using rubber stoppers. This is followed by capping (CAPSY-LC), external washing and drying of vials (WRE), and the printing of codes on the vials or caps/seals with subsequent verification by means of a camera (CODY).

We can also propose solutions for single-dose vaccines filled into Syringes: we can provide automatic machines for tub lid and liner removal, filling and stoppering of RTU Syringes in nest and tray (EXTRAFILL SERIES).

In addition, clients can choose from an extensive range of CMP Phar.ma automatic machines for the inspection of ampoules, syringes and vials, with the option to combine their chosen system with a leak test unit. Lines can also incorporate linear (SL-F425 and BL-F425) or rotary (RL-F family) labelling machines. Finally, various solutions are available for secondary packaging - including FB220, the tray thermoforming machine for ampoules, vials and syringes - and for end of line, with an extensive portfolio of medium/high-speed cartoning machines which are ideal for packaging vials, ampoules and blisters, horizontal case packers and palletisers.