Based on Stevanato’s EZ-fill platform, the new EZ-fill Smart platform is said to ensure higher product quality and improved processes in response to the rising demand for RTU vials


Gerresheimer and Stevanato have introduced EZ-fill Smart for the global vial market. (Credit: Gerresheimer AG)

German packaging manufacturer Gerresheimer and Italy-based drug containment, drug delivery, and diagnostic solutions provider Stevanato Group have officially launched the new ready-to-use (RTU)  vial platform dubbed EZ-fill Smart.

According to Gerresheimer, the platform is intended to enhance the drug packaging quality, bring down the total cost of ownership (TCO), and lessen lead times for customers.

Based on Stevanato’s EZ-fill platform, the new EZ-fill Smart platform can help improve customer product range in response to the rising demand for RTU vials.

Gerresheimer and Stevanato are said to have implemented process and product modifications that can offer significant improvements for customers.

EZ-fill Smart is said to utilise increased automation in the production process to boost output and lower human mistake rates.

Gerresheimer said that the platform avoids glass-to-glass and glass-to-metal contact to improve both the quality and integrity of the vials across the product life cycle.

In contrast to the conventional Ethylene Oxide (EtO) sterilisation, the new EZ-fill Smart is claimed to provide a more ecologically friendly sterilisation approach that serves as an alternative method for more safety.

The platform incorporates recommendations made by regulatory agencies and is designed to be suitable for use in highly sensitive drugs, said the Gerresheimer. EZ-fill Smart also improves sustainability through packing efficiency and the use of biopolymers and recycled plastic, added the company.

Gerresheimer executive board member Lukas Burkhardt said: “As an innovative and leading solution provider for the Pharma and Biotech industry, Gerresheimer responds to customer demand with a best-in-class solution.

“We are convinced that the new EZ-fill Smart platform is the next industry standard for Ready-to-Fill vials and in the future also for cartridges.”

Developed in collaboration with machine vendors, EZ-fill Smart is designed to provide seamless integration with standard fill and finish operations. Additionally, the platform supports both small and big batch production, said Gerresheimer.

Alongside the Nest & Tub configuration, EZ-fill Smart will be offered in tray configuration to support and hasten the transition from bulk to RTU vials, Gerresheimer said.

During the first half of 2024, EZ-fill Smart with Nest & Tub configuration, including process and product optimisation, is anticipated to be made available for the commercial phase.