The Story of the E-lab filler:
Every idea starts with a question.
Every idea starts with a question.
After building SmartFiller, a compact but complex platform, we realized that many users had different needs.
They needed flexibility, speed, and the freedom to move from manual to automatic filling without changing their entire setup.
We started working in parallel on two lines:
one highly sophisticated, and one simple, accessible, and modular.
That’s how the E-Lab Filler was born.
They needed flexibility, speed, and the freedom to move from manual to automatic filling without changing their entire setup.
We started working in parallel on two lines:
one highly sophisticated, and one simple, accessible, and modular.
That’s how the E-Lab Filler was born.
From the idea to the prototype and real life
Our first real challenge Comedical request, in 2023
Our first real challenge came with Comedical, in 2023.
Comedical has a very interesting story. It is a small company with an interesting range of very specific products. If you want to know more about them and their products see here: Homepage - Comedical and for its story: Comedical: storia e prospettive future
Comedical has a very interesting story. It is a small company with an interesting range of very specific products. If you want to know more about them and their products see here: Homepage - Comedical and for its story: Comedical: storia e prospettive future
| Simplicity is about subtracting the obvious and adding the meaningful They needed to fill special vials with long internal spoons: a process that required a complete and compact solution. The available space was extremely limited. Cleanliness and ease of maintenance were mandatory. The budget, on the other hand, was far from what a standard industrial machine would require. At the same time, the project was even more demanding: it needed high flexibility, scalability, compactness, and full traceability. Andrea Gardumi, CEO of Comedical, also asked for a very fast realization. It didn’t go that fast, to be honest because we wanted to test every corner, improve every detail, and make sure it was perfect. We started to perform the filling operations ourselves, becoming part of the process to truly understand the real challenges of their work: handling small, delicate components while wearing full hygienic clothing: Tyvek suits, gloves, masks, caps... It’s not easy when something goes wrong in such conditions, really, shit happens then. To understand it even better, we began working on a manual setup, to feel the effort and precision required when you must fill and cap 300–400 pieces per hour. It’s absolutely not an easy task. Not at all. We can assure you and now we understand the operating personnel in cleanrooms. So we worked, we made mistakes, and we worked again - improving step by step - until the machine could finally run on its own with full confidence. The outcome? The first E-Lab Filler prototype — a scalable core module, extendable with add-ons for loading, capping, and labeling. It worked beautifully and immediately caught the attention of other labs facing similar challenges. From that point, the story took off. And so did the requests for new improvements. But as curious and passionate engineers... we couldn’t step back. |
Additional functions and new challenges
What should have been very plain was becoming increasingly technologically advanced.
At the end of 2024, new customers started asking for many additional features and Pharma-level precision in filling.
So we began talking about a whole new set of requirements for what was supposed to be “only” a basic filling machine, simple to operate and dedicated to the medical devices sector, particularly in the diagnostics field.
What happened next? Let’s find out…
So we began talking about a whole new set of requirements for what was supposed to be “only” a basic filling machine, simple to operate and dedicated to the medical devices sector, particularly in the diagnostics field.
What happened next? Let’s find out…
| Pharma Like Design and improvement in filling technology The first requests focused on cleanability and ease of changeover. As always, we couldn’t say no, so we redesigned the architecture of the first version, creating a “suspended-in-air” layout to keep the working area completely free from obstructions and particle accumulation. We started using Pharma-grade O-rings and FDA-approved gaskets, applying them in every area that could be considered a potential liquid-retention or contamination zone. We truly adopted a Pharma-like design philosophy, emphasizing hygienic design principles such as smooth surface transitions, minimal dead zones, and full accessibility for cleaning and inspection. Everything was progressing until one customer asked us to modify the machine so it could be installed inside an ISO Class 5 isolator for DNA sample container handling. That time, we had to decline! The machine was not yet ready for such a radical redesign to comply with totally aseptic process requirements. However, the path was clearly leading in that direction. We already had customers interested in using such a compact system inside isolators operating under strict environmental control and Grade A/ISO 5 conditions. We are planning a parallel version of the machine specifically for that environment, expected by the end of 2026. In the meantime, we continue improving the current model to progressively approach those standards. Even so, for standard medical device assembly or diagnostic reagent filling, the machine is becoming a benchmark in terms of architecture, flexibility, changeover efficiency, interoperability, and ergonomics. The working table is fully accessible, and the carousel, along with all components involved in a format changeover or required for thorough cleaning, can be disassembled by an unskilled operator in a matter of seconds. All functional parts of the machine are isolated and can be replaced as independent modules, without any special tools or technical expertise. This is why, when operators or users approach the machine, they can’t help but appreciate it, realizing how intuitive and supportive it is from every point of view. |
The Story of E-Lab Filler — Chapter 2: Different filling precision requirements
The Project Within: An Advanced Pharma Peristaltic Pump
We were used to being asked for a filling precision of ±1–2% on standard volumes, typically ranging from 2 mL up to 20 mL or more. But new customers began requesting extremely small volumes and much tighter tolerances.
Moreover, in certain applications, a volumetric pump was not the optimal choice, due to its tendency to apply shear stress to delicate molecules, particularly proteins and peptides.
For this reason, we decided to completely revisit our peristaltic pump line. We launched an extensive R&D program aimed at developing a specialized, high-precision peristaltic pump, designed according to the best practices established by leading experts in the field.
The project required time, persistence, and multiple design iterations. Many prototypes were built, tested, and refined as we explored the impact of subtle geometric and operational parameters.
But in the end, we succeeded, truly succeeded. Today, we are also recognized as a solution provider for customers seeking their own customized, pharma-oriented peristaltic pump.
A great deal of know-how has been acquired, and significant results have been achieved.
Moreover, in certain applications, a volumetric pump was not the optimal choice, due to its tendency to apply shear stress to delicate molecules, particularly proteins and peptides.
For this reason, we decided to completely revisit our peristaltic pump line. We launched an extensive R&D program aimed at developing a specialized, high-precision peristaltic pump, designed according to the best practices established by leading experts in the field.
The project required time, persistence, and multiple design iterations. Many prototypes were built, tested, and refined as we explored the impact of subtle geometric and operational parameters.
But in the end, we succeeded, truly succeeded. Today, we are also recognized as a solution provider for customers seeking their own customized, pharma-oriented peristaltic pump.
A great deal of know-how has been acquired, and significant results have been achieved.
| Designing a New Line of Peristaltic Pumps: Technical Challenges and Engineering Insights Speaking about peristaltic pumps is no small thing. It is everything but easy and certainly not simple. The concept may rely on an old patent, yet its countless configurations and applications make it a technology that can be completely redefined even today. Beyond the great amount of work spent refining our existing solutions and selecting the most appropriate components, we discovered so many boundary parameters that, at certain moments, we even wondered whether this was truly our mission. For instance, who would have thought that one of the most critical parts of these devices is not only the pump itself, but also its accessories, especially the tubing? The tubing plays a fundamental role: its mechanical and material properties directly affect the pump’s performance. Even the most advanced peristaltic head will fail to achieve consistent filling precision if the tubes are not of high quality or correctly matched to the operating conditions. Tubing elasticity, specific curing, inner diameter tolerances, wall thickness, and fatigue resistance determine both flow repeatability and pressure stability. Small deviations can lead to drift, pulsation, or variations in volumetric accuracy. Validation procedures, test parameters, operating conditions, and measurement instruments are also crucial. They must be aligned if one wants to compare results with the reference data obtained from our pumps under steady-state laboratory conditions. In fact, even if the nominal specifications of peristaltic pumps sound incredible — for example, 0.5–1% precision on a 0.1 mL filling volume — the real-world results, even from well-known manufacturers, can differ substantially once speed, tubing wear, and different motion profiles come into play. Tubing wear is, by itself, a whole story. No tube manufacturer provides guaranteed lifetime data that exceed a single operating shift, for very clear reasons. The variability in materials, extrusion processes, and surface finishing makes standardization nearly impossible. Inner diameter tolerances as small as ±0.05 mm can completely change compression ratios, and therefore flow accuracy and repeatability. And if tubing makes such a difference, so do the filling needles. They are manufactured in a wide range of materials, from stainless steel AISI 316L to titanium or PEEK, but geometry is what really matters. The internal finish, bevel angle, and tip shape all play a crucial role depending on the liquid type, its viscosity, and the filling application. A smooth inner surface reduces turbulence and foaming, while the right external geometry avoids dripping or air bubble formation at the end of filling. In short, designing a peristaltic pump means balancing a complex ecosystem of mechanics, materials science, and fluid dynamics. Months of testing and refinement led to outstanding performance and reproducibility. |
| Why a Step Feeder?: Technical Challenges and Engineering Insights At that point, the conventional bowl feeder didn’t fully meet the requirements. While bowl feeders can handle continuous high-speed feeding, they typically require a large hopper to ensure autonomy, increasing overall height, noise, and vibration. In laboratory environments, especially in diagnostics, these factors can become critical. That’s why we decided to design a dedicated Step Feeder for the E-Lab Filler. Unlike bowl feeders, the Step Feeder lifts components in discrete steps using synchronized paddles or plates instead of vibration. This principle offers several advantages in our specific context: Pros
Cons and trade-offs
The Step Feeder enables the E-Lab Filler to store and feed vials autonomously throughout the entire batch, while maintaining the small footprint, flexibility, and quiet operation that define the system. This design choice marked a turning point: a new generation of add-ons, more modular, more autonomous, and much quieter, perfectly aligned with the core principles of the E-Lab Filler. |
The Story of E-Lab Filler — Chapter 3: Add-ons
The Project Within: Special Add Ons, Feeders, Manipulators, Labelling units
Compact autonomy: new Step Feeders for pre-capped vials
When we first introduced the E-Lab Filler, it was designed to be a flexible, compact, and user-friendly filling system.
But as soon as the first machines started operating in the field, our customers began to ask for more: higher productivity, a minimal footprint, and easier add-on management.
That’s where the next step of evolution began.
To increase throughput without expanding the layout, we developed a dedicated family of Step Feeders fully compatible with the E-Lab Filler platform.
These feeders are designed specifically for pre-capped vials, making the machine completely autonomous in vial feeding and handling: no manual intervention, no additional footprint.
Their mechanical design allows quick assembly and disassembly, while keeping maintenance simple and access intuitive.
Only two cables are required to connect and manage each add-on, one for power, one for communication, making integration truly plug and play.
Smooth lines, easy access, high cleanability, and full remote serviceability complete the concept.
Each add-on is an independent module that operates in combination with the main E-Lab Filler unit.
When we first introduced the E-Lab Filler, it was designed to be a flexible, compact, and user-friendly filling system.
But as soon as the first machines started operating in the field, our customers began to ask for more: higher productivity, a minimal footprint, and easier add-on management.
That’s where the next step of evolution began.
To increase throughput without expanding the layout, we developed a dedicated family of Step Feeders fully compatible with the E-Lab Filler platform.
These feeders are designed specifically for pre-capped vials, making the machine completely autonomous in vial feeding and handling: no manual intervention, no additional footprint.
Their mechanical design allows quick assembly and disassembly, while keeping maintenance simple and access intuitive.
Only two cables are required to connect and manage each add-on, one for power, one for communication, making integration truly plug and play.
Smooth lines, easy access, high cleanability, and full remote serviceability complete the concept.
Each add-on is an independent module that operates in combination with the main E-Lab Filler unit.
The connection From Step Feeder to E-Lab Filler
The Project Within: Smart Solution and fast change over.
Quick Connection for Rapid Changeover
One of the main goals behind the Step Feeder design was to keep the changeover process as fast and clean as possible.
To achieve this, we developed a compact, tool-free vials transfer system that can be attached or removed in seconds.
The mechanical interface is based on two knurled knobs, which lock the module securely in place and can be released instantly for format change or for switching between loading modes.
This design makes the system completely cleanable, with smooth surfaces and no hidden areas where residues could accumulate.
Following one of the core principles of E-Lab Filler - no compressed air anywhere in the machine - we also developed a new type of gate to control the vial loading on the carousel.
It’s a simple, extremely clean and functional mechanism, never seen before on the market. (see here how it works: LINK)
The gate consists of a circular selector made of POM (or PEEK, depending on the customer’s requirements), connected to the main unit through a single waterproof cable.
A second cable controls the sensor positioned at the inlet of the descent channel.
Thanks to these two IP65 bayonet connectors, the entire system — Step Feeder, gate and sensors — can be disconnected, cleaned, or replaced immediately.
The result is a fully modular, hygienic and maintenance-friendly assembly that perfectly matches the design philosophy of the E-Lab Filler: simplicity, flexibility, and total absence of compressed air.
One of the main goals behind the Step Feeder design was to keep the changeover process as fast and clean as possible.
To achieve this, we developed a compact, tool-free vials transfer system that can be attached or removed in seconds.
The mechanical interface is based on two knurled knobs, which lock the module securely in place and can be released instantly for format change or for switching between loading modes.
This design makes the system completely cleanable, with smooth surfaces and no hidden areas where residues could accumulate.
Following one of the core principles of E-Lab Filler - no compressed air anywhere in the machine - we also developed a new type of gate to control the vial loading on the carousel.
It’s a simple, extremely clean and functional mechanism, never seen before on the market. (see here how it works: LINK)
The gate consists of a circular selector made of POM (or PEEK, depending on the customer’s requirements), connected to the main unit through a single waterproof cable.
A second cable controls the sensor positioned at the inlet of the descent channel.
Thanks to these two IP65 bayonet connectors, the entire system — Step Feeder, gate and sensors — can be disconnected, cleaned, or replaced immediately.
The result is a fully modular, hygienic and maintenance-friendly assembly that perfectly matches the design philosophy of the E-Lab Filler: simplicity, flexibility, and total absence of compressed air.
| Beyond Step Feeders: When Flexibility Becomes the Key There are applications where even the most efficient Step Feeder reaches its natural limits. When instant changeover, wide component compatibility, or multi-part assembly are required, for example when both vials and their caps must be transported and loaded, or when syringes and plungers need to be handled and assembled directly on the machine, the Step Feeder alone may not be the optimal solution. In these cases, productivity and efficiency can be affected if components have significantly different geometries, materials, or feeding behaviors. That’s why we decided to take a step further, integrating flexible feeding technologies designed to adapt dynamically to each product configuration. Working closely with our customers, we evaluate the best feeding strategy for each project. When ultimate flexibility is required, we employ the flexible vibratory feeding systems developed in collaboration with our partner Industry Devices. These systems combine:
It eliminates the traditional barriers of production limited to a few or very similar formats, opening the way to a true multi-format environment, where different components can be handled within the same platform simply by changing the software recipe. Once again, this evolution was not born from theory but from real production needs. Customers asked for a system that could adapt to any component, any geometry, any sequence — and E-Lab Filler evolved accordingly, maintaining its signature traits: compactness, modularity, and simplicity of use. |
ELab Filler: Software & UI (Medical/Pharma)
The Project Within: modular software environment
Let’s take a closer look at the modular software environment within the E-Lab Filler system.
Each module has been developed based on real feedback and operational needs collected over the years from our clients across various regulated sectors, ensuring readiness for even the most specific and emerging requirements.
The software architecture follows GAMP 5 guidelines, making it proactive toward any potential CFR 21 compliance requests.
It is accessible directly from the machine by operators with different roles and access levels, as well as from authorized network-connected devices.
We designed an interface that issimple, intuitive, and user-friendly, so that it can be used by anyone — not just technical staff or specialized operators.
The system supports a wide range of applications: from hospital-based filling operations to beauty industry packaging, and of course, to ISO 5 laminar flow environments for the preparation of medical devices, and, in the near future, pharmaceutical products.
Each module has been developed based on real feedback and operational needs collected over the years from our clients across various regulated sectors, ensuring readiness for even the most specific and emerging requirements.
The software architecture follows GAMP 5 guidelines, making it proactive toward any potential CFR 21 compliance requests.
It is accessible directly from the machine by operators with different roles and access levels, as well as from authorized network-connected devices.
We designed an interface that issimple, intuitive, and user-friendly, so that it can be used by anyone — not just technical staff or specialized operators.
The system supports a wide range of applications: from hospital-based filling operations to beauty industry packaging, and of course, to ISO 5 laminar flow environments for the preparation of medical devices, and, in the near future, pharmaceutical products.
| Case Studies, what we learnt E-Lab Filler is an integrated hardware and software platform designed for the control, traceability, and digital documentation of filling and packaging processes in regulated diagnostic and medical environments. The system ensures Data Integrity, complete traceability, and smart automation integrated with mechatronic and vision components. Our know-how builds on extensive experience in the automation of filling processes through SmartFiller machines, developed for filling luer-lock syringes for the European and U.S. markets. The final device was typically subject to terminal sterilization (steam or gamma) and contained 0.9% saline solution, classified as a Class IIb or III medical device, depending on its intended market. In such cases, the need for full process control and traceable production history was a mandatory requirement. Our clients required: recipe validation and continuous process validation in line with each approved recipe. The work order created by the production manager defined the recipe, the quantity, and automatically included all variable data associated with the batch and printed on the label. The software tracked the complete lifecycle of each syringe — from filling to release or rejection — with all records stored both locally and in a dedicated repository. Access control and role management, following defined hierarchies and permissions, are essential to maintaining system integrity in accordance with international standards. |
ELab Filler: Filling of very variable Diagnostic Medical Devices
The Project Within: Configuration challenge
The most typical case studies involving E-Lab Filler systems concern the filling of diagnostic medical devices.
Here too, regulatory and customer-driven requirements have become increasingly strict, focusing on automated control and complete traceability of every production event.
Automation demands have evolved significantly: for instance, the ability to acquire a QR code directly from the system to log in, or to automatically upload authorized work order data when the process is not directly managed by a corporate MES or ERP.
At the same time, machine configuration interfaces have become more customizable, as clients now require the management of many different product types on the same machine.
Here too, regulatory and customer-driven requirements have become increasingly strict, focusing on automated control and complete traceability of every production event.
Automation demands have evolved significantly: for instance, the ability to acquire a QR code directly from the system to log in, or to automatically upload authorized work order data when the process is not directly managed by a corporate MES or ERP.
At the same time, machine configuration interfaces have become more customizable, as clients now require the management of many different product types on the same machine.
- Flexibility and Scalability Requirements.
- Manual loading of very small round vials (5–8 mm), with fully automatic uncapping, filling, and recapping.
- Manual loading of cylindrical vials containing internal paddles or similar components attached to the cap (e.g., DNA RNA Shield fecal collection tubes), again with fully automatic uncapping, filling, and capping.
- Manual loading of complex-shaped bottles for specific analytical purposes, also managed with fully automated operations.
| Productivity Challenges As productivity increased, clients requested automatic component loading while maintaining compact, plug-and-play systems with auto-configuration capabilities. We therefore developed stand-alone benchtop stations, which can be configured for either fully automated or semi-manual operation as needed. As you can imagine, the software complexity behind such flexibility is considerable — yet the result is a smart, intuitive, and robust system architecture. There are applications where even the most efficient Step Feeder reaches its natural limits. When instant changeover, wide component compatibility, or multi-part assembly are required, for example when both vials and their caps must be transported and loaded, or when syringes and plungers need to be handled and assembled directly on the machine, the Step Feeder alone may not be the optimal solution. In these cases, productivity and efficiency can be affected if components have significantly different geometries, materials, or feeding behaviors. That’s why we decided to take a step further, integrating flexible feeding technologies designed to adapt dynamically to each product configuration. Working closely with our customers, we evaluate the best feeding strategy for each project. |
ELab Filler: Modular Architecture and Advanced Features
The Core of E-Lab Filler Intelligence
At the heart of the E-Lab Filler ecosystem lies a software platform engineered to bring compliance, automation, and scalability together in a single, seamless environment.
Technology Pillars
Compliance First
Built on international standards such as GAMP 5 and CFR 21 Part 11, the platform ensures full role-based access control, audit trails, and synchronized timestamps.
Every action is traceable and authorized, maintaining the highest levels of data integrity and regulatory compliance.
Smart Automation
The system’s intelligence adapts to your process. Automatic machine configuration, guided changeover, and an AI-driven vision system for cap, fill, and closure verification guarantee reliable results and drastically reduce human error.
Cloud Ready
Through secure cloud connectivity, operators and managers can monitor equipment remotely, manage machine fleets (FARM), and synchronize data with ERP or MES systems.
Multi-site management and predictive analysis keep your production connected and always under control.
Scalable by Design
Whether managing a single batch or an entire production line, E-Lab Filler grows with your needs.
Each module can be activated independently, creating a scalable ecosystem that evolves with your workflow.
- Designed for regulated medical production, it combines data integrity, process efficiency, and intuitive usability, ensuring that every batch, every fill, and every record is managed with precision and confidence.
Technology Pillars
Compliance First
Built on international standards such as GAMP 5 and CFR 21 Part 11, the platform ensures full role-based access control, audit trails, and synchronized timestamps.
Every action is traceable and authorized, maintaining the highest levels of data integrity and regulatory compliance.
Smart Automation
The system’s intelligence adapts to your process. Automatic machine configuration, guided changeover, and an AI-driven vision system for cap, fill, and closure verification guarantee reliable results and drastically reduce human error.
Cloud Ready
Through secure cloud connectivity, operators and managers can monitor equipment remotely, manage machine fleets (FARM), and synchronize data with ERP or MES systems.
Multi-site management and predictive analysis keep your production connected and always under control.
Scalable by Design
Whether managing a single batch or an entire production line, E-Lab Filler grows with your needs.
Each module can be activated independently, creating a scalable ecosystem that evolves with your workflow.
| Modular Architecture: Tailored to Your Process Base Module:
Optional Modules / Premium Functions
Customer Value: Why It Matters
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| Stay tuned — the next chapter is coming soon. ...For the next chapter and to have more details... some days and we come back... The new chapter will be about Addition Ann Ons and Software Integration Requests :) |
Images credits: wikimedia commons | wikimedia
All text, photo, and video materials belong to their owners and are for demonstration purposes only. Please do not use them in commercial projects.
All text, photo, and video materials belong to their owners and are for demonstration purposes only. Please do not use them in commercial projects.