COP/COC polymer vial filling machine

Characteristics of COP/COC polymer vials

COP/COC vials are optimized for the storage and filling of sensitive products, particularly in biotechnology. Their design meets the strict requirements of aseptic environments and automated filling processes.

Technical specifications:

• Material: COP/COC
• Volume: 2–20 mL
• Closure: Stopper + crimp
• Packaging: Sterile RTU (Ready-To-Use)
• Intended use: Sensitive biologics (mAbs, vaccines)

COP/COC materials offer significant advantages: excellent chemical inertness, high break resistance, low extractables, and ideal compatibility with aseptic filling operations. These transparent, lightweight, and robust polymers also facilitate visual inspection. However, their lower gas barrier compared to glass requires specific validation depending on the product and its stability profile.

Applications and industry use

COP/COC vials are particularly well suited for the most demanding segments of the pharmaceutical industry. Their growing adoption stems from their compatibility with sensitive biological products and cold-chain processes.

Application areas:

• Biotechnology and bioproduction: Fragile formulations requiring extremely low container–product interaction.
• Biological products: Monoclonal antibodies, recombinant proteins, peptides.
• Vaccines: Conventional and next-generation platforms.
• Advanced therapies: Cell and gene therapies requiring highly controlled environments.
• Aseptic filling & cold chain: Enhanced stability and processes adapted to refrigerated or cryogenic conditions.

COP/COC vials stand out for their mechanical resistance, improved safety (no breakage), and compatibility with laminar airflow and ISO 5 classified environments, making them a preferred choice for modern aseptic lines.

Aseptic lines designed for COP/COC vials

A modern COP/COC polymer vial filling machine integrates into an automated aseptic line designed to ensure total product integrity from decontamination to final crimping.

Key features of a dedicated aseptic filling line:

• Controlled aseptic transfer of RTU vials in nests or trays.
• High-precision filling systems suitable for small volumes (2–20 mL) and a wide range of viscosities.
• Automated crimping module ensuring reproducible closure in compliance with pharmaceutical standards.
• In-process controls: statistical weighing, particle detection, machine vision.
• Laminar airflow environments and integrated sterile zones to maintain zero microbial load.
• Advanced automation: operator interface, traceability, MES integration, and GMP/Annex 1 compliance.

Equipment from manufacturers specialized in aseptic technologies—particularly systems inspired by modern filling engineering—deliver enhanced safety, optimal repeatability, and full adaptability to polymer containers. Their mechanical and software design ensures gentle handling of COP/COC vials, preventing deformation and enabling high throughput under sterile conditions.