Optimizing Automated Filling with Custom Upright Trays

Client Overview

A long-standing compounding pharmacy using MPS Pharma’s standard ophthalmic droppers was entering a new stage of growth. As prescription volume increased, their manual filling process could no longer keep pace. To scale efficiently and maintain the highest quality and aseptic standards, the pharmacy invested in an automated filling line housed within a Restricted Access Barrier System (RABS). They needed a packaging solution compatible with both their new equipment and the physical constraints of their cleanroom environment.

The Challenge

While the automated filling equipment promised throughput and consistency, a critical challenge emerged at the point of loading bottles onto the turntable inside the RABS.
Key obstacles included:

• RABS Physical Barriers: Operators were unable to reach across or inside the system to manually orient or manipulate bottles. Every container entering the RABS needed to be pre-loaded in a precise, upright position.
• Ergonomics & Cleanroom Restrictions: Operators, dressed in full cleanroom garb and gloves, needed packaging that was compact, easy to open, and simple to place within the RABS without compromising aseptic conditions.
• Workflow Compatibility: The bottle orientation had to be reliable and repeatable to avoid downtime, jams, or misfeeds on the new automated line.

The pharmacy needed a custom solution that would allow them to leverage automated filling without disrupting the rigor of their cleanroom operation.

The Collaboration

MPS Pharma partnered directly with the pharmacy’s operations and engineering teams to observe their current workflow and understand the constraints imposed by the RABS environment. Through collaborative working sessions, we gathered detailed requirements around:

• RABS access limitations
• Turntable dimensions and bottle spacing
• Operator handling needs
• Cleanroom packaging requirements

By mapping the client’s new automated workflow step-by-step, MPS was able to co-design a packaging strategy that supported both sterility and efficiency.

The Solution

MPS Pharma engineered a custom upright bottle tray specifically designed to meet the operational needs of a RABS-based fill line.
Key features of the tray solution:

• Precise Bottle Orientation: Each tray was manufactured with cavities sized exactly to the client’s chosen bottle, allowing MPS to load bottles in a perfectly upright position—ready for seamless transfer to the turntable.
• RABS-Optimized Footprint: The tray dimensions were intentionally compact, enabling operators to comfortably handle and position the trays while fully gowned in cleanroom apparel.
• Intuitive, Easy-Open Design: The packaging was designed to open quickly without excessive manipulation, reducing operator strain and minimizing time within the RABS work zone.
• Pre-Loaded at MPS Facility: Bottles arrived to the pharmacy already upright and organized, eliminating the need for technicians to reorient or manually prep components.

By engineering a packaging system around their operational constraints, MPS ensured the new automated line could run smoothly from day one.

Implementation Process

Because the pharmacy was already using the selected bottle type, no additional stability or compatibility testing was required, accelerating the timeline.
MPS worked closely with the pharmacy technicians to:

• Validate the tray’s fit and ease of use
• Conduct hands-on trials under real RABS operating conditions
• Confirm ergonomics and handling comfort for cleanroom operators
• Incorporate technician feedback into the final tray design

This collaborative, iterative process ensured that the packaging integrated naturally into the pharmacy’s workflow with no disruption to production.

The Results

The pharmacy achieved a seamless transition to their new automated RABS filling line.
Key outcomes included:

• Reliable Automated Bottling: Bottles could be loaded quickly and consistently, reducing manual handling and risk of misfeeds.
• Improved Operator Efficiency: The easy-to-handle trays allowed cleanroom staff to work comfortably within RABS constraints.
• Operational Scalability: With the new packaging system in place, the pharmacy is now equipped to support continued growth without sacrificing aseptic standards.