By Dec Group
Subscribe to Supplier
Subscribe to Supplier
Dec Group Launches DecFill® XP, Ushering in a New Era of Compact Aseptic Filling
Ecublens, Switzerland – Dec Group has introduced DecFill® XP, a next-generation aseptic filling platform engineered to set a new benchmark for compact design, sustainability, and operational reliability in fill-finish manufacturing.
As regulatory expectations tighten under EU GMP Annex 1 and manufacturers pursue smaller, more sustainable facilities, aseptic production platforms must deliver higher output with reduced complexity. DecFill® XP responds with a fundamentally re-engineered approach to primary packaging handling.
Levitating Shuttle Transport Simplifies Fill-Finish
At the heart of DecFill® XP is an advanced magnetic levitation shuttle system that replaces traditional multi-station mechanical transfer. Instead of separate loading, filling, stoppering, and crimping stations, the platform integrates the process into a continuous Unlock–Fill–Close workflow within a single compact cabinet.
The contact-free magnetic shuttles transport vials with high positional accuracy, reducing friction, particle generation, and mechanical wear while minimizing contamination risk.
Key performance advantages include:
- Nearly 50% reduction in linear installed length from approximately 13 meters for conventional lines to just 7 meters for a single DecFill® XP workstation
- Increased manufacturing density per square meter
- Reduced utilities and facility requirements
- Lower energy consumption and operational carbon footprint.
Sustainable, Pre-Validated Vial Integration
DecFill® XP is compatible with a new generation of closed, pre-validated sustainable vials designed for magnetic transport. These ready-to-use formats eliminate washing and sterilization steps, enabling:
- Faster batch start-up
- Reduced breakage and process risk
- Elimination of sterilized sorting bowls
- Improved Annex 1 alignment
- Measurable energy savings
By reducing product contact parts and simplifying infeed, the platform enhances both compliance and environmental performance.
Reliability Through Reduced Complexity
By eliminating unnecessary mechanical functions and limiting components entering the isolator, DecFill® XP improves process robustness and operator accessibility.
Benefits include:
- Approx. 25% equipment cost savings
- Reduced FTE requirements
- High automation with fewer interventions
- No stopper or cap entry into the isolator
DecFill® XP represents a decisive shift toward smaller, smarter aseptic filling systems designed for modern pharmaceutical manufacturing.
About Dec Group
Founded in 1987, Dec Group is a Swiss based leading global provider of powder handling and process containment systems to the pharmaceutical, chemical, food and cosmetic industries.
Dec products offer a high level of safety for both operator and product. Their advanced system concepts, from the standard powder transfer system to highly complex integrated handling and processing equipment, allow clients to increase productivity while respecting stringent regulatory requirements.
Over the past years, Dec Group has carried out a significant expansion of its activities with the acquisition of specialized companies. The company today has divided its products into 5 distinct divisions: Powder Handling, Continuous Processing, Particle Size Reduction, Containment Solutions, and Filling Solutions. Together, these offer true end-to-end solutions from the raw material input to the final dosage form.
To learn more, visit: https://www.dec-group.net/
Resources:
DecFill® XP replaces a traditional multi-workstation aseptic fill-finish platform with a compact integrated single-cabinet system in which the simplified complete Unlock–Fill–Close workflow is executed.
DecFill® XP-compatible vials designed for magnetic transport are supplied ready-to-use and require no washing or sterilization prior to filling.
Related Articles
