Telstar Integrates Vial Rejection Module into Automatic Vial Loading and Unloading Systems

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Telstar has developed an innovative in-line vial management system for recognition and marshaling of vials in automatic loading and unloading systems.

Telstar’s intelligent vial rejection module (IVRM), displayed at ACHEMA, is an in-line manipulation system designed for detection and treatment of vials during the freeze-drying process. The system is a compact in-line quality control unit that can be fully integrated in automatic loading and unloading systems to automatically manage the paths of vials during the loading and/or the unloading of freeze dryers. 

The IVRM has two main functions: the detection and subsequent management of a specific vial in the process line. The module is able to identify and separate a specific vial according to different parameters (e.g., stopper position, missing stopper, and color variation). After identification, it is capable of performing several tasks: rejection of the vial to a rejection container, separation of vial for sampling, separation of one vial for a specific function, introduction of a pre-prepared vial or re-introduction of a vial subsequent to removal.

The IVRM represents a compact and versatile solution for in-line vial management at high speeds, ensuring appropriate processing of lyophilized products as well as reducing the risk of batch contamination, spoilage, and the time of operator intervention.


Telstar’s new generation of vial loading and unloading systems can be integrated with freeze dryers, offering robustness, efficiency, reliability, and accuracy in the vial transport and transfer process, in addition to easier cleaning and simplified maintenance. The improvements are mainly concentrated in the transport conveyor transition modules and in vial alignment systems, which offer increased security of vial transport in loading and unloading processes, resulting in elimination of breakage and significant reduction in rejects. The improvements include new vial descrambling modules that are suitable for unloading processes up to 400 vials per minute with a typical rejection rate of 0.01%. Telstar has also introduced an ultra-compact loading mechanism that results in a 40% reduction in the space required in the clean room.

Source: Telstar, Hall 3.1, Stand C49