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Robotic Precision in Small Batch Aseptic Processing

The GENiSYS® R aseptic small batch filling and closing machine from Automated Systems of Tacoma offers aseptic filling and closing of ready-to-use vials, syringes, and cartridges, enabled with robotic arms completing delicate and repetitive tasks.

A Stäubli TX2 series Stericlean robot presents vials for secure stoppering with reliable repeatability and no risk to the aseptic environment.
A Stäubli TX2 series Stericlean robot presents vials for secure stoppering with reliable repeatability and no risk to the aseptic environment.

Growing demand for small batch processing poses new challenges for the life sciences sector, as the healthcare industry trends toward drugs more tailored to certain patient populations. Adapting to variances while maintaining quality, efficiency, and adherence to aseptic processing requirements is more complex than ever.

Automated Systems of Tacoma (AST) is a U.S.-based pharmaceutical machine manufacturer specializing in advanced aseptic filling equipment and packaging machines, and a pioneer in the use of robotics in the fill/finish industry. With a relationship spanning more than two decades, AST chose Stäubli robotics in 2010 to develop a multi-format robotic filling machine–the first ever capable of processing different types of container formats on a single machine.

AST launched its GENiSYS R in 2018; this flexible modular system automates aseptic filling and closing of ready-to-use vials, syringes, and cartridges in strict accordance with CGMP requirements. It can be integrated with isolator-barrier or RABS technologies to maintain required aseptic conditions in tightly controlled ISO 7 and ISO 5 environments. 

The GENiSYS R is optimized for small batch filling, with a focus on dosing precision and high yield, and uses robotics to achieve 100% in-process control (IPC). This makes it ideal for clinical and commercial applications in drug manufacturing, compounding, cell and gene therapy development, personalized medicine, cytotoxic drug processing, and other areas.


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The IPC provides real-time fill weight feedback and control, which can be used to identify issues early on, ensuring quality, minimizing waste, and maximizing product yield. Electronic batch record (EBR) software records key production data that can be used to create 21 CFR Part 11-compliant batch reports.

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Break out of the ordinary: see what’s new in life sciences packaging