Agent 01 · fill-and-dose
Micro-tolerance filling on your most fragile molecules.
Shear-sensitive biologics punish overfill, foaming, and splashing with rejected units worth thousands each. The fill-and-dose agent controls weight, pump rate, and dynamics in real time to land every dose inside spec.
The problem
Every drop is a decision worth thousands.
A single overfilled or foamed vial of a high-value biologic is scrapped, not reworked. Traditional fill control runs on fixed recipes that can't react to viscosity drift, pump wear, or temperature within the shot.
- Fixed recipes ignore in-shot dynamics.
- Foaming and splashing wreck CCI downstream.
- Manual weight checks are sampled, not continuous.
How it works
Sense, model, control, inside every shot.
- 01
Sense in-process
Continuous weight, pump feedback, and dynamics captured at the needle, not sampled after.
- 02
Model the fluid
A physics-informed model predicts foaming and shear from viscosity and speed in real time.
- 03
Control the pump
Rate and ramp adjust mid-shot to land weight without splashing the shear-sensitive product.
- 04
Log for release
Every fill is recorded with an attributable Part 11 trail for review by exception.
Capabilities
Built for the hardest fills.
Viscosity adaptation
Compensates for lot-to-lot viscosity drift without recipe changes.
Foam suppression
Predicts and avoids foaming that would fail container-closure integrity.
Peristaltic & TT pumps
Works across peristaltic, rotary piston, and time-pressure fillers.
100% weight checks
Every unit weight-verified, not statistically sampled.
Reject at source
Out-of-spec units diverted before they consume downstream capacity.
Yield reporting
Live yield and loss attribution surfaced per lot for CI teams.
Precision
±0.02% accuracy, shot after shot.
Because control happens within the shot rather than between them, drift never accumulates. The agent holds the tolerance band across shift changes, lot changes, and pump wear.
Validate it in the twin first →Under the hood
Grounded control, not a black box.
In-process weight & dynamics
High-rate sensing at the fill point feeds the model every millisecond.
Fluid physics
Shear and foaming predicted from product properties, not guessed.
Bounded pump control
Adjustments stay inside a validated envelope, reviewable and reversible.
Fixed recipe vs. Sterira
Reactive beats pre-set.
| Behavior | Fixed recipe | Fill-and-dose agent |
|---|---|---|
| Reacts to viscosity drift | No | Yes |
| Predicts foaming | No | Yes |
| Weight verification | Sampled | 100% |
| Part 11 record per unit | Partial | Complete |
"We stopped scrapping high-value units to foaming. The agent holds tolerance through pump wear that used to force a mid-shift recalibration."
Biologics CDMO
Next in the line
Explore adjacent agents.
FAQ
Common questions.
No. The agent integrates with existing peristaltic, rotary-piston, and time-pressure fillers over their control interface.
It starts advisory, then graduates to closed-loop control within a validated envelope once your QA team signs off on the twin results.
Shear-sensitive biologics, mAbs, vaccines, and any high-value fill where overfill and foaming carry real cost.
Prove ±0.02% on your line.
Pilot the fill-and-dose agent on one line and measure the yield.