Aseptic Flexible Filling Line - Integrated Project Services - IPS
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Aseptic Flexible Filling Line

Cook Pharmica was awarded the 2017 Facility of the Year Award (FOYA) for Equipment Innovation for the execution of their project to expand manufacturing capabilities. Utilizing state-of-the-art robotic technology, the flexible filling line (FFL) is capable of processing syringes, cartridges, and both liquid and lyophilized vials.

3D scan of Cook Pharmica Aseptic flexible filling line

IPS partnered with Cook to overcome the challenges of integrating new equipment within the existing facility in order to implement the bold and unique vision for this FFL. IPS coordinated with equipment suppliers to determine optimal systems integrations, creatively utilizing the available footprint. 3D laser scanning of the facility and 3D design tools were deployed to ensure our team could design into the space within fractions of an inch.


Many challenges were involved in incorporating a new process into an existing facility. Such a unique approach demanded a high-level of coordination to integrate the filling line, isolator AHUs, and lyo mechanical equipment in the technical space and penthouse areas, while maintaining material and personnel transitions of the original facility.