In cell and gene therapy, where fill precision and cell viability can determine the success of an entire treatment, it's surprising how many manufacturers still rely on manual pipetting to fill cryovials. Given the criticality of this step, the risks associated with manual handling, such as contamination and operator error, are simply too great. The good news is that a more robust solution is now a reality.
Manual pipetting might be widely used, but it’s far from efficient. Highly skilled technicians spend valuable time transferring cell suspensions by hand, carefully pipetting each vial, often under sterile conditions. It’s tedious, repetitive work that demands a high degree of skill and focus. Yet even the most experienced hands can introduce variability. One small error, one moment of lapse, and you’re facing inconsistencies in cell volume, potential contamination, or worse, damage to the very cells you're trying to preserve.
Beyond the technical pitfalls, there's a growing strategic challenge. As the demand for advanced therapies rises, so too does the need for skilled biochemists and cell therapy specialists. But the talent pool isn’t growing fast enough. With global shortages of highly trained staff, relying on labour-intensive, manual steps just isn’t scalable anymore.
The industry is feeling this squeeze from both ends: on one side, pressure to reduce manufacturing costs; on the other, a regulatory push for more standardised, reproducible processes. The use of cryoprotectants, such as DMSO, enables cryogenic storage by preventing the formation of ice crystals. However, these very cryoprotectants can destroy cells at room temperature: the time from DMSO addition to cell freezing needs to be consistent and as short as possible. When you add in the complexity of autologous therapies, where each batch represents an individual patient’s (often life-saving) therapy, there’s very little margin for error, and even less time to waste.
This is where automation makes all the difference.
By switching to an automated cryovial filling solution, such as award-winning cryoFIL®, manufacturers remove one of the most error-prone, resource-heavy steps from their process. The result isn’t just faster throughput, it’s better outcomes at every level. Automation ensures each vial is filled with consistent volume, minimal shear stress, and optimal preservation conditions. The system handles the dosing, transfer, and sealing with precision, freeing up skilled staff to focus on higher-value activities.
Crucially, the process is designed to be operator-friendly. You no longer need a team of specialist technicians to achieve quality results. With the right technology in place, teams can be trained quickly; production becomes more resilient and depends less on individual expertise.
The benefits speak for themselves. When the process is automated, we see higher cell survival rates, thanks to gentler handling and closed-loop control. Processing times drop dramatically. Quality control becomes more robust, with built-in data capture and traceability supporting regulatory compliance.
But perhaps the most important impact isn’t in the lab. It’s with the patient.
By simplifying and standardising cryovial filling, we help bring therapies to market faster. We make treatments more accessible by reducing cost and complexity. And we give patients, some of whom are waiting for life-changing or even life-saving interventions, a better chance at receiving a consistent, effective treatment.
At 3P innovation, we believe automation isn’t just about efficiency. It’s about unlocking the full potential of cell therapy, ensuring that every dose, every vial, every cell is given the best possible chance to make a difference.
So, if your team is still pipetting cryovials by hand, it might be time to ask: how much is that costing you, in time, in quality, in opportunity?
Reach out today to see cryoFIL®, our automated cryovial filling solution, in action and discover how we’re helping shape the future of cell therapy manufacturing.