Introducing DecFill® XP - A New Era in Aseptic Filling

Aseptic manufacturing is changing rapidly, driven by the need for greater efficiency, sustainability, and operational simplicity. DecFill® XP embodies this evolution with a disruptive concept that reimagines how primary packaging moves through the fill‑finish process. Combining a revolutionary levitating transport system with next‑generation sustainable vials, DecFill® XP sets a new benchmark for compact, energy‑efficient, and highly reliable aseptic production.

A Breakthrough Levitating Transport System

At the core of DecFill® XP is a levitating transport technology that eliminates the mechanical complexity of traditional filling lines. Instead of multiple handling stations - loading, filling, stoppering, crimping, etc. - the entire workflow is condensed into a single, continuous Unlock‑Fill‑Close sequence. Vials glide smoothly on levitating shuttles, reducing friction, wear, and contamination risks while simplifying the overall architecture.

This streamlined approach delivers major operational advantages:

• Drastically reduced footprint: Only 7,000 mm in length versus ~13,000 mm for a standard line

• Higher manufacturing density: More output within the same facility area

• Lower building and infrastructure impact: Smaller manufacturing area, reduced utilities, simplified layouts

• Lower operational carbon footprint: Fewer components and less energy‑intensive equipment

  
  

The result is a smarter, more compact system that is easier to operate, maintain, and scale.

Sustainable, Pre‑Validated Primary Packaging

DecFill® XP supports a wide range of formats, including a new generation of closed, pre‑validated sustainable vials designed to reduce environmental impact without compromising sterility or performance. Because these vials require no washing or sterilization, manufacturers benefit from:

• Faster batch starts

• Reduced process risk and lower breakage rates

• Smoother, more reliable infeed

• Significant energy savings 

• Better alignment with Annex 1 thanks to fewer product‑contact parts and no need to sterilize sorting bowls

These advantages accelerate time to market while supporting greener, more responsible production.

A Simpler, More Reliable Aseptic Line

By eliminating unnecessary mechanical functions and reducing the number of components entering the isolator, DecFill® XP enhances process robustness and operator accessibility.

Key benefits include:

• Approx. 25% equipment cost savings

• Reduced FTE requirements due to simplified operation

• More reliable process with fewer line functions and no stopper/cap entry into the isolator

• High degree of automation

DecFill® XP is engineered to deliver consistent performance with fewer interventions and lower overall risk.

A New Standard for Modern Aseptic Manufacturing

DecFill® XP is more than an incremental improvement - it is a fundamental rethinking of aseptic filling. With its levitating transport system, sustainable vial compatibility, and dramatically simplified process flow, it offers manufacturers a future‑ready solution that delivers:

• Smaller footprint

• Lower costs – CAPEX/OPEX

• Higher reliability

• Reduced environmental impact

• Faster time to market

For organizations seeking a next‑generation aseptic platform that combines innovation with practicality, DecFill® XP represents a decisive step forward.