IMA EDWARDS is one of the few suppliers in the world that designs, manufactures and tests a full range of proven systems for fully automatic loading and unloading vials into industrial freeze dryers. The systems are designed to continuously transfer vials from the liquid filling equipment to the freeze dryer and from the freeze dryer to the alu-capper. We have all the necessary expertise and production facilities in-house, ensuring the highest quality standards on the entire configuration. Systems for use with vials are tray-less, operate at constant loading level and can be configured under laminar flow or fully isolated.  Depending on the configuration, these systems can perform multiple scheduled tasks such as loading one freeze dryer while unloading another.

Video Clip Lyomax Loading Sequence

Two types of loading systems are available: Fixed or Flexible. The decision as to which loading system is right for you depends upon:

• Number of freeze dryers to be operated
• Line processing speed
• Range of vials to be processed
• Clean room space available
• Stability of the product
• Clean room classification (EMEA class A,B,C,D or US 100, 1000, 10000)
• Length of the freeze drying cycle
• Distance from the filler and capper to the freeze dryer
• Need to load/unload the freeze dryer from a single side or pass-through configuration

Fixed Loading Systems
Fixed automatic loading systems are generally a more cost-effective solution when one or two freeze dryers require loading, and simultaneous operation is not required for loading and unloading. More freeze dryers can be supported if they are in pass-through configuration.

Flexible Loading Systems
Flexible loading systems can serve multiple freeze dryers and perform multiple scheduled tasks.  Loading systems consist of a loading accumulation table (LAT), integrated with the out-feed of the fill line, which collects and moves vials in a vial pack equivalent in shape and size to each freeze dryer shelf. Once a vial pack is created on the LAT, a Transfer Cart (TCAR) collects the vial pack and transfers the pack onto the designated freeze dryer shelf. At the end of the freeze drying process, the TCAR collects the vial packs from the designated freeze dryer shelf and transfers the vial pack to an unloading accumulation table (UAT) or Unloading Accumulation Buffer (UAB), where the vials are de-scrambled for single lining to the alu-capper.  
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Semi-automatic Loading Systems
This Semi-automatic Tray Loading System provides a controlled and reproducible solution for loading fences in/out of a freeze dryer, avoiding manual interaction with the vials and product, and reducing intervention with the fences to an absolute minimum.

The systems are used with trays (bulk) or with fences (for vials), operate at ‘constant loading level’ and can be configured under laminar flow with open or closed RABS (Restricted Access Barrier System).

The Tray Loading System consists of the following standard modules:

• A fence loading table for automatic loading of vials in fences.
• A movable transfer cart supported by a rail/guide system for transfer of fences between the fence loading table, the freeze dryer and the single lining table.
• A single lining table, consisting of an unloading platform with a rotary table to single line the vials towards a capper.