- Gerresheimer AG

Best-in-class Gx® Elite Vials that make your life easier with our new improved RTF platform solution

Gx Elite EZ-fill Smart® Vials

Gx Elite EZ-fill Smart® Vials

Gx Elite EZ-fill Smart® Vials comes as a highly standardized platform for streamlined and flexible pharma operations with highest product quality and reduced particle contamination risks, all while ensuring top-tier vial consistency and quality.

De-risking of fill & finish
Risk-free processing and seamless integration into standard fill & finish lines from all major machine vendors No glass-to-glass and reduced glass-to-metal contact

Low particles supporting Annex 1
>90% particle reduction creating a new standard for the benefit of drug product safety

Supply chain security
Risk mitigation through like-for-like standard of two leading global manufacturer

Alternative sterilization option
Introduction of VHP as safe, sensitive and environmentally friendly method for sterilization matching with FDA expectations

Benefits of the Gx Elite EZ-fill Smart® Vials

De-risking of fill & finish

Risk-free processing and seamless integration into standard fill & finish lines from all major machine vendors. No glass-to-glass and no glass-to-metal contact

Low particles – improved quality

>90% particle reduction creating a new gold standard for the benefit of the patient

Supply chain security

Risk mitigation through like-for-like standard of two leading global manufacturer

Alternative sterilization

Safe and more environmentally friendly method for sterilization of complete system incorporating guidelines given by regulatory bodies

Sustainability: Reduced CO2 footprint

Use of biopolymers and re-usable materials, weight reduction, vials produced with green energy

Reduced TCO

Reduced cost and investment driven by smaller machine footprint due to centralized processing of washing/depyrogenization

New Tub Design

Package description

by performance level

Component

Mateiral

Properties / Features

Transparent peelable Polymer Lid

Opaque
HDPE/PE

  • Ensures sterility with a hermetic seal for ultimate product protection

  • Easy-to-remove peelable design streamlines operations

  • Reduces particulate contamination during opening.

Gx® Elite Glass Vials 2R to 20R

Type 1
Borosilicate

  • Flawless appearance and unmatched mechanical strength enhance product reliability

  • Precision manufacturing ensures virtually no lot-to-lot and inner-lot variation

  • Optimized for maximum production efficiency and minimal reject rates

Nest

Polypropylene
homopolymer

  • Prevents glass-to-glass contact for superior protection against breakage

  • Universal design guarantees compatibility with standard fill-finish lines

  • Simplifies production processes with easy integration.

Tyvek Stripes

HDPE

  • Permeable barrier supports multiple sterilization methods

  • Hermetic sealing ensures closure integrity for sterility assurance

  • Positioned for compatibility and seamless integration with standard fill-finish equipment.

Tub

High impact
Polypropylene
peterophasic
copolymer

  • ISO 11040-7 compliant design 

  • 3-inch tub for all vial sizes and future cartridges 

  • Holds permeable Tyvek barrier for gas sterilization

Boxes

Polypropylene

  • Safeguard packages for handling and transportation

  • Allow for terminal sterilization by EtO (ethylene oxide)

  • or VHP (vaporized hydrogen peroxide)

Sterilization

EtO, VHP

  • Terminal sterility of product to assure SAL 

  • Proved sterility according ISO norms

Comparison Bulk vs. RTF Manufacturing

Bulk Line Processing

Complex Processing

  • Washing by WFI (70°C+)
  • Heat tunnel for sterilization (up to 350°C)
  • Additional failure modes
  • High efforts by quality

RTF Line Processing

Efficient Processing

  • Focus only on Fill & Finish process: no washing, 
    no heat tunnel
  • High-quality packaging directly entering filling line
  • Lower space requirements due to reduced footprint
  • Reduced number of operators to run the line

Improvements with VHP Sterilization

  • Sterilization method leaning towards current FDA expectations,  with less toxic impact by sterilization
  • No risk of harmful by-product of sterilization phase to be released in the environment
  • Different sterilization methods available for customer to decide how to “phase” the switch from current sterilization methods to other
  • No need to modify current validated test methods at customer site. In line with guidelines given by regulatory bodies
 - Gerresheimer AG

Take Advantage of our wide Range of Capabilities

  • Production sites in Europe, Americas and Asia for risk mitigation
  • Expansion coefficients 33 and 51
  • Inner siliconization for optimum emptying
  • Ammonium sulfate treatment to reduce alkali ion emission
  • Optimized design for lyophilization processes
  • Fully validated processes and certified suppliers according to cGMP
  • Ph. Eur., USP, JP, FEUM compliance
  • DMF type III
 - Gerresheimer AG

High-Technology Gx® G3 Vial Inspection

  • Proprietary visual inspection systems ensure cosmetic and dimensional quality.
  • Visual inspection of all areas of the vial: finish/neck, shoulder, body, hyper-bottom
  • Combination of 5 high resolution matrix and line-scan cameras
  • Proprietary lighting system
  • Custom software capable of defect recognition and classification
  • Bright and dark field images acquired at the same time help to characterize defects
  • Precision handling system for repeatability

Matching Accessories

Contact us!

Polymer Vials

Europe & Asia
Vials (plastic)
Phone: + 49 160 741 59 39
E-Mail: Wolfgang Dirk

USA
Vials (plastic)
Phone: +1 404 376 8157
E-Mail: Franck Langet

Glass Vials

Europe & Asia
Vials (glass)
Phone: +49 9342 9281-25
E-Mail: Lothar Haaf

USA
Vials (glass)
Phone: +1 (770) 652-0659
E-Mail: Polina Golovatch