Skip to the main content.

Reconstitutable powder filling system for global MedTech client

Custom Automation - Case Study

Reconstitutable powder filling system for global MedTech client

This custom aseptic reconstitutable powder filling system, developed for our pharma client, integrates two distinct powders into a single medical device, enabling precise, sterile reconstitution. Our custom automation expertise enables customers to advance product and process innovation across diverse industries.

The challenge

The project required the sterile integration of two separate powders into a single device while maintaining strict GMP compliance throughout the entire process.

Unlike conventional powder filling applications, the system needed to manage two formulations with differing material characteristics and dosing requirements, all within a tightly controlled aseptic environment. Achieving reliable and repeatable dosing at very low fill weights introduced significant technical complexity, particularly given the sensitivity of the powders and the precision required by the final product.

The client required:

  • High-precision filling performance capable of maintaining dosing accuracy within ±1–2%
  • Rapid cycle times of under 30 seconds per unit to support high-volume production
  • Fully aseptic processing compatible with isolator integration
  • Robust containment and environmental control to protect both product integrity and operator safety
  • Reliable handling of powders with challenging properties, including poor flow and potential segregation risks

In addition to the technical requirements, the system also needed to be flexible enough to support ongoing product development and future process optimisation.

Why 3P innovation?

The client selected 3P innovation based on our extensive expertise in precision powder dosing and our proven capability in designing equipment for aseptic and isolator-based manufacturing environments. Our ability to combine powder handling knowledge with custom automation engineering allowed us to develop a solution that addressed both the pharmaceutical and mechanical complexities of the project.

FLS-2-1
FLS_1920px (37 of 37)-1
FLS_1920px (19 of 37)
FLS_1920px (7 of 37)

Our process

We employed an iterative design approach, rigorously evaluating multiple powder dosing technologies to identify the most effective solution for the client’s formulation and process requirements. Because the system needed to accurately dispense two distinct powders within tight tolerances, extensive testing was carried out to understand powder behaviour, flow characteristics and dosing repeatability under aseptic conditions.

Throughout development, we refined both the filling methodology and the overall machine architecture to improve performance, reliability and manufacturability. This included optimising powder transfer paths, minimising material loss and integrating environmental controls to maintain sterility within the critical process area.

To support the required production throughput while maintaining a compact footprint, we also redesigned the product containers into a square format. This improved space efficiency within the machine, simplified handling and enabled more effective integration of the automated filling and transfer systems.

The final solution combined:

  • Precision dosing technology capable of achieving ±1–2% fill accuracy
  • Automated handling systems to support cycle times under 30 seconds per unit
  • Isolator-compatible design principles for aseptic processing
  • Flexible machine architecture to accommodate ongoing product development
  • GMP-focused engineering with cleanable, containment-conscious design

Results and future collaborations

The completed system delivered significant operational improvements for the client, dramatically increasing process efficiency while maintaining the high standards required for aseptic pharmaceutical manufacturing.

Processes that previously required extensive manual intervention were streamlined through automation, improving consistency and reducing operator dependency. The system also reduced the risk of sample cross-contamination while enabling highly skilled personnel to focus on higher-value technical activities rather than repetitive manual preparation tasks.

In addition to improving throughput and dosing reliability, the platform provides a scalable foundation for future product development and manufacturing expansion. Building on the success of this collaboration, we look forward to supporting the client with future automation and aseptic processing projects.

Explore other powder dosing technologies from 3P innovation