Gerresheimer AG and Stevanato group launch vial platform

Ready-to-fill EZ-fill Smart for global vial market

EZ-fill Smart, a solution designed to improve drug packaging quality (Gerresheimer)

Gerresheimer AG and Stevanato Group announced recently at CPhl Worldwide the official launch of a new and innovative ready-to-use vial platform, EZ-fill Smart, a solution designed to improve drug packaging quality, reduce total cost of ownership, and shorten lead times for customers. 

Gerresheimer AG, a leading global provider of healthcare & beauty and drug delivery systems for pharma, biotech and cosmetics and Stevanato Group, a global provider of drug containment, drug delivery and diagnostic solutions to the pharmaceutical, biotechnology and life sciences industries. 

The new EZ-fill Smart is an evolution of Stevanato Group’s groundbreaking EZ-fill platform, and it brings new advancements that can create significant enhancements to customer product offerings amid growing demand for RTU vials, says press release. 

The companies have implemented process and product changes that can offer substantial improvements for customers. The EZ-fill Smart platform leverages increased automation throughout the manufacturing process to increase productivity and reduce human errors. The optimized platform features no glass-to-glass and no glass-to metal contact, which improves quality and integrity of the vials throughout the product life cycle. 

The new EZ-fill Smart now offers the market a sterilization method that is more environmentally friendly compared to traditional ethylene oxide sterilization, and that is an alternative sterilization method that can result in improved safety. 

Together, Stevanato Group and Gerresheimer AG have obtainedpositive results to date and are in the validation process with this sustainable sterilization method. EZ-fill Smart is intended to improve sustainability in multiple areas, increasing the packaging efficiency, implementing a new eco-friendly sterilization method, and using biopolymers and recycled plastic.  

Developed in close cooperation with major machine vendors, EZ-fill Smart can provide a proven seamless integration with standard fill & finish operations. The platform also accommodates both small and large batch production. The companies have implemented advancements that can help ensure the processability on filling lines with the primary aim to facilitate the complete automation of the in-feeding process. 

EZ-fill Smart with Nest & Tub configuration, including process and product optimization, is expected to be available for the commercial phase during the first half of 2024. By mid-2023 the new solution is expected to be available to customers for initial validation. EZ-fill Smart with tray configuration for high volume, is expected to be available on the market during the first half of 2024.  

“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”, said Lukas Burkhardt, member of the executive board of Gerresheimer AG. “The new platform will enable customers to optimize their processes, improve their quality and also their carbon footprints. In addition, our customers benefit from a significant reduction in the total cost of ownership.”  

“Our EZ-fill technology is a well-established standard in the industrial process for RTU primary containment solutions, and the new and innovative EZ-fill Smart platform responds to increasing demand from customers for RTU products”, said Mauro Stocchi, chief business officer, Stevanato Group. “We believe EZ-fill Smart will help pharma companies, CMOs, and CDMOs easily adopt the market-leading technology by optimizing quality, costs, and machinability while keeping our environmental impact in mind”.  

EZ-fill Smart has officially been presented at CPhI Worldwide on November 1-3, 2022, in Frankfurt at Gerresheimer AG (booth 30 B21 in hall 3.0) and Stevanato Group (booth no 30F30 hall 3.0). 


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