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- Pharmaceutical
Vial Breakage Eliminated for Seqirus
100% Vial Breakage Eliminated, Saving 3-4 Hours Per Incident at Seqirus
3-4 hours of downtime saved per incident
100% reduction in vial breakages
Increased scroll speed and smoother transfer
Supported flu vaccine output during critical delivery windows
The Challenge
Seqirus’ vaccine production line was facing repeated issues:
Fragile vials (size 2215) were breaking mid-transfer
Each breakage triggered full line cleanups and sterilization
Downtime per incident reached 3-4 hours
Delays threatened public health supply timelines
The Solution
AE engineered a new scroll system designed for precision:
Isolated stress points and optimized vial handling
Redesigned the scroll for stable high-speed transfer
Achieved zero-breakage performance post-install
Delivered fast with no rework or further adjustment needed
Outcome
| Metric | Result |
|---|---|
| Breakage Rate | Dropped to 0% |
| Downtime per Incident | Saved 3–4 hours each time |
| Scroll Performance | Faster and smoother with full stability |
| Compliance | Fully aligned with sterile production protocols |
"Since installing the new scroll, we have not experienced any of the vial breakages that were previously affecting production. The vial transfer is smoother, and we’ve increased speed while maintaining stability."
Seqirus
— Maintenance Support Engineer
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Struggling with fragile vials, contamination risk, or GMP compliance?
Let AE deliver sterile-ready engineering that performs under pressure.
