Healthcare Technology Featured Article

August 30, 2022

Top Trends in Sterile Manufacturing Technology

Sterile manufacturing refers to the method of producing medications in which the drug product, container, and closure are meticulously sterilized before being distributed.

The pharmaceutical sector has faced significant challenges in the last ten years due to the growing demand for aseptic vaccinations and boosters, particularly in aseptic manufacturing.

Numerous difficulties must be overcome to meet the rising demands. In order to meet these obstacles, it is necessary to maintain sterile production properly while also figuring out more accurate, efficient, and cost-effective solutions. Find below some of the tre

Split Butterfly Valve

The name of this type of butterfly valve comes from its shape. The active half and the passive half make up its two components. The filling container or drum is connected to the passive half, while the receiving vessel or producing machinery is connected to the active half.

The product's sterility is ensured since it travels through the lines without even a fleeting moment of contact with the outside environment. Because it ensures that the substance travels without being exposed, the split butterfly valve drastically minimizes the necessity for sterilization in the pharmaceutical business. Similarly, the split butterfly valve is a one-time technology.

Production Environments

Manufacturing environments are challenged to ensure that the proper control mechanisms are implemented to prevent multiple potential contamination sources as the demand for sterile drug products increases.

Operators, machinery, and other elements of the production environment are among them. If microbes, particulates, or endotoxins penetrate the manufacturing environment, patient safety may be at risk.

To guarantee the sterile transfer of products and their drug content during aseptic processing, a number of technologies have been developed by sterile pharmaceutical manufacturers throughout the years. Examples include isolators and restricted access barrier systems (RABS).

Although RABS create a barrier between workers and processing lines, they also permit workers to engage with products when needed. When utilized in cleanroom settings, isolators offer an airtight barrier surrounding the processing line and can reduce the risk of contamination.

However, RABS and isolator systems both have drawbacks. When using an isolator, materials transfer can be a challenging operation that can delay the shutdown and startup process between batches. RABS technology also relies on manual cleaning methods that, if not carefully controlled, might cause delays between usage.

Patient Focus Is Getting More and More Important

The discomfort experienced during injection is one of the main patient worries about the delivery of sterile injectable drugs. Numerous aspects of the medicine formulation, the delivery method, and the patient all impact how painful something feels.

Self-administration devices are rapidly developing too — where possible — to address numerous such issues. The dimensions and shape are intended to be ergonomic and make operating easier.

Today, many devices offer visual and auditory cues to let patients know when they need to do anything or when an automated process is finished. Sensors show when the location of the device is appropriate.

To avoid overuse and prevent needle-stick accidents, needles withdraw automatically. While some devices are made for sequential injection of two liquids, others enable single-step mixing and injection. Others permit automated lyophilized powder and water for injection (WFI) mixing, preventing possible contamination problems.

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