ZeroStop®, sterilization becomes continuous, even where it previously seemed impossible
For decades, sterilization has represented one of the main operational limitations in aseptic processes. A necessary step, but inherently slow, often organized in batch mode, and therefore unable to keep up with the pace of modern high-speed filling lines.
With ZeroStop® Sterilization Station, De Lama introduces a solution set to completely redefine this scenario. This is not just a technological advancement, but a true paradigm shift: for the first time, traditionally batch processes are transformed into a continuous operational flow, eliminating one of the biggest bottlenecks in the industry.
And let’s be clear from the beginning: this is not a conventional sterilization or depyrogenation tunnel, historically limited to dry heat applications.
From batch logic to continuous operation
Traditionally, only dry heat sterilization and depyrogenation tunnels allowed a truly continuous process. However, many applications require different technologies, such as:
– saturated steam – air/steam mixture – dry heat – superheated water – low-temperature sterilization with vaporized hydrogen peroxide (VH₂O₂)
These processes, by their nature, have always been performed in closed chambers and therefore in batch mode (with the exception of dry heat).
ZeroStop® overcomes this limitation through a completely new approach, based on years of research, advanced automated transfer systems, and the integration of intelligent control logics.
The result is a system capable of generating a continuous output, perfectly synchronized with filling lines, even at high speeds.
In practice, sterilization no longer slows down the production process, but becomes an integral part of a continuous flow.
Full integration with production lines
One of the most revolutionary aspects of ZeroStop® is its ability to integrate directly with filling lines, maintaining their pace.
In facilities producing thousands of vials per hour, any slowdown in sterilization leads to significant efficiency losses. With ZeroStop®, this issue is eliminated: the system dynamically adapts to the line speed, ensuring continuity and process stability.
The result is a drastic reduction in inefficiencies and a tangible increase in productivity.
Multi-technology and maximum flexibility
ZeroStop® is not just a continuous system, it is also an extremely versatile platform.
The station can integrate multiple sterilization technologies, including:
– saturated steam – air/steam mixture – VH₂O₂ HyPerPure® under deep vacuum – hot air – superheated water
Moreover, it is possible to combine multiple technologies within the same station, offering unprecedented flexibility and allowing companies to quickly adapt to different production needs.
A concrete response to Annex 1
The new Annex 1 guidelines place increasing emphasis on two key aspects:
– use of closed systems such as isolators or RABS – minimization of human intervention in critical areas
ZeroStop® directly addresses these requirements.
By eliminating manual loading and unloading and integrating into an automated process flow, the system drastically reduces human intervention, which is one of the main sources of contamination.
This enables not only greater regulatory compliance, but also a significant improvement in microbiological safety.
Revolutionizing production layout
One of the most tangible impacts of ZeroStop® concerns the organization of production spaces.
In traditional systems, the use of loading trolleys for sterilizers leads to:
– occupation of large areas within controlled environments – presence of structures that are often unused or empty – high handling and management costs
ZeroStop® completely eliminates the need for these trolleys.
This results in:
– recovery of valuable square meters – reduction of operational costs – simplification of plant layout – improved logistical efficiency
At the same time, repetitive and low-value manual activities are eliminated, bringing both economic and quality benefits.
A technology already in use
ZeroStop® is not a theoretical concept or an early-stage prototype.
The system has already been designed, patented, and tested, and has been adopted by leading international pharmaceutical companies, which recognize it as a true game changer.
Its introduction marks the beginning of a new era in industrial sterilization: more efficient, more integrated, and more sustainable.
The future of sterilization is continuous
With ZeroStop®, De Lama demonstrates that even the most established limitations can be overcome.
Sterilization is no longer a constraint, but becomes an enabling element of the entire production process.
A profound transformation, set to redefine industry standards in the years to come.
