UDS Filling and Assembly Systems

The TurboFil UDS Filling and Assembly Systems with VersiTrack or Starwheel are designed for the filling and assembly of single-dose nasal and unidose drug delivery devices. These systems support fully automatic and semi-automatic production workflows, making them well suited for pharmaceutical and medical device manufacturers across development, clinical, and commercial production.

For higher throughput and scalable automation, the VersiTrack platform uses a linear, servo-indexed conveyor to transport UDS components through each process station. Interchangeable holding pucks move device components — including the container, stopper, holder, and actuator — through filling, stoppering, and assembly operations with high precision and repeatability.

For development programs, clinical trials, or lower-volume production, the Starwheel workstation provides a semi-automatic alternative. This rotary indexing platform performs filling and stopper placement automatically while allowing operators to complete additional assembly steps at a controlled pace, offering flexibility without the complexity of full automation.

Both platforms can be configured with peristaltic or piston pump filling technologies depending on product characteristics and dosing requirements. All product contact components are manufactured from 316L stainless steel, ceramic, or FDA-approved materials to support compatibility with sensitive pharmaceutical formulations.

Designed for accuracy, flexibility, and compliance, these systems can be configured for use in controlled or aseptic environments. With typical production speeds around 80 units per minute, and configurations available up to approximately 100 units per minute, the systems provide a scalable pathway from development through commercial production.

Features

• PLC machine controller (Allen Bradley)

• Stainless steel vibratory bowl feeders

• Linear servo indexing conveyor system (Versitrack)

• Starwheel for indexing (Workstation)

• Ethernet capabilities for remote diagnostics (option on Workstation model)

• Liquid filling accuracy +/- 0.5%

• Suitable for aseptic environments

• Compact footprint

Speed: 80ppm with option of up to 100 ppm adjustable output

Options

• Dosing system for CIP/ SIP  conditions

• Gas flushing before, during or after the filling process

• Monitoring and particle counting

• Automatic rejection of defective devices

• Process data acquisition software in accordance with FDA 21CFR Part 11

• RABS (Restricted Access Barrier Systems)

• IQ/OQ validation package

• UL508A Certified electrical boxes

• Advanced data package