New cleanroom for smart bottle production

Published: 30-Jan-2009

Graham Packaging Plastics has invested around £1million to upgrade its cleanroom and bagging facilities in Chalgrove, Oxfordshire. This will ensure the sterile manufacture of a new container for use with culture media.

The GIBCO bottle is the result of a three-year collaboration between Life Technologies, a provider of essential life science technologies for laboratories, Graham Packaging Plastics and designers IDEO.

The bottle will be used by scientists working with cell cultures and other life science products in sterile conditions under a laminar hood. IDEO therefore studied the way scientists went about their task before designing an ergonomically coherent pack, which is easy to use, positively affects efficiency and reduces errors and contamination of samples. As a result of the analysis, eleven different bottle design prototypes were created and tested in laboratory conditions with user groups.

The chosen design provides solutions to the challenges seen during fieldwork: improved ergonomics of ‘under the hood’ workflow, superior handling and storage, easier identification and additional room for supplements. It incorporates:

  • an angled neck for easier pipetting and pouring
  • compact form for improved handling and storage
  • a wider mouth to reduce the chance of contact with the pipette
  • easy grips lids for one-handed opening

Above all however, the reduction in errors and contamination when the product is used make the best environmental case. Fewer bottles are ruined so laboratories get through their stocks in a more controlled fashion, reducing unnecessary transport and cutting waste.

Graham Packaging worked with Life Technologies during the three year planning process, adapting the chosen design to ensure a family of bottles could be made successfully. The new containers are available in 100ml, 500ml and 1 litre sizes.

Life Technologies has invested US $3.8m in the new project, which has seen bespoke filling, capping, labelling, sleeving and packing equipment made and installed at its production plant near Glasgow.

Seven different companies were involved in the investment, from the cleanroom build (Thermal Transfer), semi-automatic de-bagging (Isoma), sterile filling (Optima Group), check weighing (OCS), product transfer (Osima/Murray Packaging) labelling (PALS) and automated case packing (Bedo).

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