Automated debagger for vial filling systems
In pharmaceutical production, sterile vial filling systems require precise handling of TUBS — containers holding empty glass vials, sealed in sterile packaging.
At the client’s facility, the opening and handling of these TUBS was performed manually inside a glovebox environment (Grade C to Grade B).
Expertises
Services
Challenge
The manual debagging process involved cutting open sterile plastic packaging and transferring the TUB to the next stage of the filling line.
This created several critical challenges:
● Time-consuming manual operation
● Risk of damaging operator gloves, compromising sterility
● Potential contamination risks in a highly controlled environment
● Production delays or downtime due to inefficient handling
In pharmaceutical production, even minor contamination or delays can lead to significant financial loss and product waste.
Approach
Metvico developed a fully integrated automated debagger system, designed to fit seamlessly into existing filling lines.
The system was engineered to operate independently of machine brands, allowing flexible integration across different setups.
Development was carried out entirely in-house — from concept and prototyping to testing and final implementation.
Execution
The debagger system automates the opening of sterile packaging and prepares the TUB for the next stage of the process.
Key features include:
● Automated cutting of plastic and Tyvek packaging in a single motion
● Stainless steel 316 cutter with quick-release system
● Adjustable cutting speed and push mechanism
● Integrated transfer system for smooth handover to the filling machine
● Evacuation of packaging waste
● User-friendly interface for operators
● Designed for multiple TUB formats
The system is designed for easy automation and can operate with minimal operator intervention.
Result
● Debagging completed in less than 10 seconds
● Reduced risk of contamination and glove damage
● Improved production efficiency and workflow
● Increased operational safety (EHS compliant)
● Reliable and consistent handling of sterile components
