Benchtop UDS System for Unidose Filling, Assembly & Labeling

TurboFil’s Benchtop UDS System is a modular, end-to-end solution for small-batch unidose filling, assembly, and labeling, combining five dedicated benchtop machines into one cohesive workflow. The system begins with the Benchtop UDS Vial Filler, which delivers accurate micro-volume liquid dosing using a servo-driven ceramic pump. Filled vials then move to the Benchtop Semi-Automatic Piston Inserter, where pistons are seated to a controlled depth for consistent internal geometry. Next, the Benchtop Vial Tamper securely seats the vial into its holder using force-monitored, servo-driven tamping, followed by the Benchtop Actuator Tamper, which completes mechanical assembly by precisely installing the actuator with verified seating force. The process concludes with the Two-Station Tamp-On Labeling System, enabling accurate two-sided label application with optional lot and expiration coding. Together, these five benchtop modules operate in sequence to provide a flexible, validation-friendly UDS production platform that supports R&D, clinical, and pilot-scale manufacturing, while offering a clear path to higher levels of automation as programs scale.

Benchtop UDS Modules

Benchtop UDS Vial Filler

The Benchtop UDS Vial Filler serves as the foundation of TurboFil’s Benchtop UDS System, delivering accurate, repeatable micro-volume liquid filling for unidose device development and small-batch production.

Designed specifically for water-like and low-viscosity formulations, the system allows operators to manually place vials into precision holding pucks and initiate filling through a simple push-button interface. This approach balances operator control with highly repeatable performance.

At the core of the filler is a servo-driven ceramic pump, chosen for its ability to deliver consistent micro-doses while maintaining gentle product handling. Combined with a suck-back nozzle design, the system ensures clean, drip-free fills and minimizes product waste.

Key Features

  • Servo-driven high-precision ceramic pump

  • Accuracy up to ±1% with precision of ±0.5%

  • Drip-free suck-back nozzle design

  • 316 stainless steel filling nozzle

  • Product contact parts: ceramic, stainless steel, PTFE

  • Direct draw from customer-supplied vessel

  • Compact benchtop footprint

Speed / Throughput

  • Operator-paced, ideal for R&D and pilot production

  • Optimized for small batch and clinical volumes

  • Consistent cycle times driven by servo control

Benefits

  • Reliable micro-volume accuracy

  • Clean, repeatable filling without over-automation

  • Easy operation with minimal training

  • Scalable foundation for future automation

Benchtop Semi-Automatic Piston Inserter

The Benchtop Semi-Automatic Piston Inserter provides controlled, repeatable piston placement—a critical step in ensuring consistent dose delivery and proper UDS device performance.

Operators manually load the filled vial and piston into dedicated fixtures before initiating the insertion cycle using a two-hand safety control. This ensures safe operation while maintaining consistent mechanical alignment.

A servo-driven two-stage insertion process compresses and seats the piston to a defined depth inside the vial. This controlled motion reduces variability and protects sensitive components during assembly.

Key Features

  • Semi-automatic piston insertion

  • Two-hand safety activation

  • Servo-driven two-stage seating process

  • Defined piston seating depth

  • Precision mechanical alignment fixtures

  • Compact benchtop design

Speed / Throughput

  • Operator-paced assembly

  • Consistent cycle time per insertion

  • Ideal for development and clinical-scale production

Benefits

  • Consistent internal geometry across batches

  • Improved device performance reliability

  • Reduced risk of piston damage

  • Supports validation and process control needs

Benchtop Vial Tamper

The Benchtop Vial Tamper is designed to securely seat the filled vial into its plastic holder with controlled and repeatable force—an essential step before actuator placement.

Operators manually load the vial and holder into a dedicated fixture and initiate the tamping cycle using a two-hand safety interface. This ensures proper positioning prior to force application.

A servo-driven tamping mechanism, combined with an integrated load cell, monitors applied force in real time. This feedback-driven approach ensures consistent seating while protecting components from damage.

Key Features

  • Semi-automatic vial tamping

  • Two-hand safety activation

  • Servo-driven tamping motion

  • Integrated load cell for force feedback

  • Precision seating fixtures

  • Benchtop footprint

Speed / Throughput

  • Operator-paced operation

  • Repeatable tamp cycle times

  • Suitable for low-to-moderate batch volumes

Benefits

  • Consistent vial-to-holder seating

  • Reduced risk of component damage

  • Measurable and repeatable force application

  • Improved downstream assembly reliability

Benchtop Actuator Tamper

The Benchtop Actuator Tamper completes the mechanical assembly of the UDS device by precisely seating the actuator onto the vial holder.

Following the same controlled philosophy as the rest of the Benchtop UDS System, operators manually load the assembled vial holder and actuator before starting the cycle with a two-hand safety control.

The system uses servo-driven motion with load-cell feedback to ensure the actuator is seated with the correct force every time. This consistency is critical to reliable device function and end-user performance.

Key Features

  • Semi-automatic actuator tamping

  • Two-hand safety activation

  • Servo-driven motion control

  • Integrated load cell for force verification

  • Consistent actuator engagement

  • Compact benchtop design

Speed / Throughput

  • Operator-paced operation

  • Consistent cycle times

  • Ideal for R&D and pilot-scale builds

Benefits

  • Reliable actuator seating

  • Improved device functionality

  • Reduced variability between units

  • Finalizes mechanical assembly with confidence

Two-Station Tamp-On Labeling System (2-Side Labeling)

The Two-Station Tamp-On Labeling System is designed specifically for dual-label unidose devices, providing accurate and flexible labeling for small-batch production.

Completed UDS devices are manually placed into a puck on the first labeler, where a servo-driven tamp-on head applies the first label. The operator then transfers the device to the second station to apply the opposing label.

The system supports a wide range of label sizes and can be equipped with a thermal printer for lot and expiration date marking, supporting traceability and regulatory requirements.

Key Features

  • Two independent tamp-on labeling stations

  • Servo-driven label applicator heads

  • Label placement accuracy up to ±1/32 in (±0.8 mm)

  • Photoelectric label sensors

  • Adjustable mounting brackets

  • Optional thermal printer for lot/expiry coding

Speed / Throughput

  • Operator-paced labeling

  • Efficient two-step workflow

  • Ideal for small batch and clinical labeling

Benefits

  • Accurate dual-label placement

  • Flexible label size compatibility

  • Supports traceability requirements

  • Professional labeling without full automation