Integra
The Integra Laboratory Crimper is a small vial crimper that is ideal for development, pre-clinical, clinical, pilot and compounding pharmacy operations. Available in four configurations the Integra can meet your small batch size needs assuring the best possible seal integrity.
Ensuring Seal Integrity in Stoppered Vial Systems
The Integra features a proven three-roller sealing head driven by a precision servo actuator. A built-in load cell accurately controls sealing pressure, ensuring consistent stopper compression and reliable seal formation—even when vial height varies. By precisely managing crimping force, the Integra minimizes variability, enhances seal integrity, and delivers repeatable, high-quality results across every batch.
The stoppered vial remains the standard container closure system for parenteral drug products, but its integrity depends on proper stopper compression and secure ferrule crimping. Integra automates this critical process: the operator loads a vial, closes the guard, and initiates the cycle. The actuator applies the programmed sealing force, the rollers form the crimp, and the system confirms completion on the Operator Interface. The result is a robust, leak-proof seal that safeguards sterility, stability, and product reliability.
Designed for precision, safety, and ease of use, the Integra embodies Genesis engineering excellence. It brings laboratory accuracy to production-scale sealing, ensuring every vial is sealed to the highest standards of integrity and performance.
Integra Platform Overview
Across all configurations, the Integra platform maintains the hallmark three-roller sealing head and servo-driven actuation with integrated load-cell force control. Whether you’re running a single-vial manual setup or a semi-automated indexing system, you get consistent crimping pressure and reliable seal formation—even when vial height or component tolerances vary. Tight control of sealing force reduces variability in stopper compression, strengthening the seal and supporting long-term product stability.
For small-batch work and development environments, the Single Vial Unit offers maximum operator oversight with production-grade sealing technology. Manual loading keeps the process hands-on for R&D, characterization, and DOE studies while preserving the full sealing-force control architecture. It’s ideal when precision, flexibility, and traceability matter more than raw throughput.
When higher output is required, the Integra Starwheel configurations step up productivity while retaining the same sealing core. The 8-pocket compact variant fits isolators or laminar-flow hoods and is well-suited to clinical and pilot operations that need a smaller footprint. The 12-pocket starwheel increases indexing capacity for semi-automated workflows—an efficient sweet spot for niche commercial lots and scale-up scenarios—while maintaining repeatable force control and seal quality.
All Integra models feature pharmaceutical-grade construction with stainless steel frames, clear safety enclosures, and an intuitive touchscreen HMI. Along with capabilities—such as recipe memory, data capture, audit-ready electronic records, network integration, and VHP-friendly designs—support compliance and connectivity within modern fill-finish facilities. In short, the Integra line blends precision engineering, regulatory readiness, and flexible throughput to support applications from R&D through small-scale manufacturing.
Key Benefits
- Seal Integrity by Design: Servo-controlled actuation and load-cell feedback deliver precise, repeatable stopper compression.
- Process Consistency: Three-roller sealing head produces uniform crimps across variable vial heights and component lots.
- Scalable Configurations: From single-vial R&D to starwheel and turntables for higher throughput, all share the same sealing core.
- Operator-Friendly: Clear guarding, simple load-and-cycle workflow, and HMI confirmations streamline daily use.
- Regulatory Support: Data capture and audit-ready records help align with validation and compliance needs.
The Integra is Available in Four Different Configurations
Single Vial Unit
The Base Model - One vial package loaded at a time by the operator. This simple and efficient design is perfect for low to medium production volumes or laboratory settings. The manual loading process allows for careful inspection of each vial while maintaining consistent crimping quality.
Compact Starwheel Unit
A 8 pocket starwheel in a compact size making it ideal for use in smaller spaces. This compact configuration features a minimal footprint while maintaining high efficiency. The starwheel indexes vials through the crimping station at a constant rate, allowing for smooth, continuous operation. Perfect for facilities that need automated vial processing within the confined spaces of isolators and laminar flow hoods.
Starwheel Unit
The Starwheel Unit features a larger 12 pocket constant indexing starwheel, designed to significantly increase throughput for higher production demands. This configuration enables the simultaneous processing of multiple vials, with each pocket securely holding a vial as it moves through the crimping station in a smooth, continuous motion.
Dual Turntable Unit
A dual turntable unit allowing for up to 200 vials to be processed at a time. This configuration is ideal for high-volume production environments where throughput is critical. The dual turntable design enables the processing of larger vial batches, significantly increasing efficiency and productivity.