Automating The Process Of Filling Media Into Bottles

A biopharmaceutical manufacturer based in Latin America specializes in the production of live-attenuated vaccines. The upstream processing (USP) of these vaccines focuses on cultivating high density cell cultures, which are later used for virus activation and amplification. For these bioprocessing steps in cell expansion and virus propagation it is required to use media and buffer solutions.

To maintain sterility and process flexibility, the company uses single-use bottles and 3D bags for aseptic media filling. The process accommodates a wide range of container formats – from bottles of 30mL to 2000mL, to large 3D single-use bags ranging from 50L to 200L.

Complex media filling operations

Due to the large variety and quantity of containers – up to 20 single-use bottles and 3D bags per batch – the manufacturer faces significant operational challenges. This complexity reduces efficiency and limits flexibility, particularly when adapting to varying batch sizes or container formats. Manual filling in a biosafety cabinet or isolator carries significant safety risks, raising the chance of contamination and jeopardizing product sterility. Together, these factors impede scalability and process robustness—making automation and closed-system solutions ever more essential.

Read the case study about how the manufacturer could boost efficiency with automated & precise bottle filling.