Aseptic Filling Systems

PDC Aseptic Filling Systems specializes in the design and manufacture of innovative filling solutions used by major Biopharmaceutical companies. Through years of development, testing, and validation by major Biopharmaceutical companies, PDC’s technology allows for aseptic filling within any clean room classification, at a fraction of fixed stainless steel system cost and manifold filling cost. Further, through the use of proprietary disposable fill system liners, customers have a fully disposable option eliminating the risk of cross contamination and eliminating much of the cost of cleaning and documentation at all levels of pharmaceutical production.

PDC manufactures aseptic filling systems featuring a unique disposable sterile fill line. Aseptic filling systems are available to fill bottles, bags or drums from 5mL up to 1000 Liters. PDC's disposable filling lines offer single use non-contact aseptic filling that can be custom designed for a variety of biopharmaceutical filling applications.

Aseptic Filling Benefits

Containers Aseptically Filled

Bag Filling Machines

Tube Sealer

Bench Top Filler

Aseptic Filling Benefits

PDC's AFL line of aseptic fillers uses a removable single-use fill line that slides into the aseptic filler making your aseptic fill non-contact and completely disposable offering the following benefits:

Validated Aseptic Filling – Proven performance. Validated Aseptic.
- Gamma irradiated single-use filling lines
- Class 100 filling zone
- Real time continuous particle counting
Decreased Risk of Cross-Contamination – Paramount to all processes is the elimination of cross-contamination risk. PDC’s single-use filling line eliminates the possibility of cross contamination.
Eliminate Cleaning Requirements – PDC's AFL aseptic filling systems eliminate clean-in-place and steam-in-place requirements. All product contact parts are single-use disposable components.
- Eliminate CIP/SIP cleaning
- Reduce WFI water use
- Reduce filling room space requirements by 75%
- Reduce filling labor by 60%
- Reduce disposable cost by 25% to 30%
- Reduce turnaround time
- Reduce reporting and documentation
Quality Assured Efficiencies – Reduce set-up time. Improve filling production. Minimize lost product and decrease the amount of disposable waste. PDC’s disposable/single-use filling products can help with quality assured cost effective aseptic filling.
Minimize Disposable Waste - PDC's single-use system is a model of efficiency allowing you to realize all the benefits of single-use filling without the problem of waste disposal. Aseptically fill your batch with the PDC system and the total waste generated is only thirty feet of disposable tube, a small fraction of the waste generated by manifold filling systems.
Reduce Capital Investment in Facility and Equipment – PDC's aseptic filling systems will help you reduce your clean room filling space requirements, and all the fixed utilities needed to support conventional stainless steel systems.

Containers Aseptically Filled

Bags From 25 mL to 50 Liter (smaller sizes also available)	Bottles From 5 mL to 2 Liter	From 50 Liter to 500 Liter

Single-Use Aseptic Filling

Fill into Large Carboys & Drums	Fill using the Integral Bag Shelf	Filling using an Ergonomic Articulating Bag Handling Table	Custom Bag Handling Tables

	Small volume fills from 100 mL To 5L rest on the bag shelf	Tables dock to the filling machine and release for easy and ergonomic bag transport to the next station.	Transfer tables are designed and manufactured to meet specific customer requirements and integrate with the production process.

Bag Filling Machines

Semi-Automatic Bag Filler

Bag Fills From 100 mL To 2 L Under Class 100 Laminar Flow

Automatic Form Fill Seal
FG2500	CS1000

2500 IV Bags Formed And Filled Per Hour	1000 IV Bags Formed And Filled Per Hour

Tube Sealer

The ThermoElectric Tube Sealer will seal thermoplastic tube from 1/8" up to 1 1/2".

PLC Sealing Controls

Each tube has unique sealing parameters. PDC tests each tube to develop a qualified seal cycle. The seal cycle is programmed into the PLC to assure each seal is an optimal seal.

Qualified Seals

PDC tests each tube seal cycle program to assure the seal is stronger than the tube itself. During seal cycle testing, the seal is pressure tested to hold 40 psi or until the tube bursts.

Fault Notification

The PLC will display a fault if any critical seal cycle parameter is not achieved.

Tube Sealing Selections

PDC loads a seal cycle program into the PLC for each tube the customer intends to seal. When changing from one tube to another, the operator simply selects the appropriate tube from the seal menu on the PLC.


1/2"	3/4"	1 1/4"	1 3/8"

Sample Cycle Times for Various Tube Sizes
Tube Size	Seal Time*
1/8"	120 sec
1/4"	130 sec
1/2"	150 sec
3/4"	155 to 170 sec
1"	200 to 230 sec
1 1/4"	205 to 240 sec
1 3/8"	215 to 260 sec
*Average seal times. Seal times vary depending upon tubing composition. Test data and seal cycle parameters are available upon request.