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VialArch™

Sensor module for in-line HSA and CCIT of vials

VialArch™, Sensor module for in-line HSA and CCIT of vials

Fast, Accurate, and Non-Destructive — with Easy Integration

The VialArch™ sensor module is an integration-ready solution offering non-destructive headspace analysis (HSA) for direct installation onto existing production lines by end users or into inspection machines by OEMs.

Powered by advanced laser-based optical spectroscopy, the VialArch™ enables up to 100% in-line quality inspection of residual oxygen and supports the validation of container closure integrity testing (CCIT). This is essential for detecting gas ingress in oxygen-sensitive pharmaceutical products.

How does it work?

As containers pass through the sensor module on the conveyor belt, a laser scans the headspace of each vial or ampoule, analyzing its gas content. This allows for fast, accurate, and non-destructive in-line container closure integrity testing (CCIT) through headspace analysis (HSA), without the need for consumables or purging.

Thanks to automatic triggering, setup is minimal. The only parameters required are container diameter and belt speed, which can be easily defined by the operator via the integrated user software or a connected control system.

Applications for the VialArch™

The VialArch™ is designed for non-destructive inspection and quality assurance of pharmaceutical containers such as vials and ampoules. It is ideal for container closure integrity testing (CCIT) in the manufacturing of oxygen-sensitive drugs. Common use cases include measuring residual oxygen in liquid-filled vials and identifying leaks in lyophilized vials.

While optimized for pharmaceutical production, the VialArch™ can also be applied to other packaging formats requiring oxygen measurement and container integrity testing, provided the sensor module is compatible with the container.

Available Variants

  • VialArch™ O₂ – Measures residual oxygen and detects pressure changes caused by gas ingress.
  • VialArch™ H₂O – Measures total and partial pressure levels.

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LineArch

Also availale as integration ready machine.

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Seamless integration, Minimal effort

With its compact footprint on the production line the VialArch™ is an innovative and integration-ready solution designed for the pharmaceutical industry.It is easy to install, calibration free, and provides measurement sampling and evaluation directly within the module. This enables quick upgrades or retrofits to existing production lines.

With the VialArch™ there is no need for daily maintenance or calibration due to its self-calibrating functionality. With minimal setup required, this solution is as close to a plug-and-play solution you will get, making it easier than ever to integrate headspace analysis (HSA) into your production line, increasing quality and consumer safety.

Support and Optimization

Every Gasporox sensor includes the Gasporox Measurement Concept, offering complete integration support. Our team works closely with you to ensure the sensor is optimized for your specific product, container, and machine setup.

We are committed to helping you achieve the best possible performance across your entire inspection process.

Key Features and Technical Highlights

  • High-performance headspace analysis (HSA)/headspace gas analysis (HGA)
  • Delivers accurate and reliable non-destructive measurements
  • Compact design for seamless integration into production lines
  • Compatible with a wide range of machine interfaces and automation systems
  • Long operational lifetime with minimal maintenance
  • Capable of analyzing low, residual, and high oxygen levels in sealed containers
  • Designed in compliance with Good Manufacturing Practice (GMP) guidelines
  • Deterministic container closure integrity (CCI) test method according to USP <1207>

Technology

The VialArch™ optical gas sensors are built on more than 25 years of development and refinement in industrial laser-based gas measurement. The system uses Tunable Diode Laser Absorption Spectroscopy (TDLAS), a highly reliable and precise method for non-destructive headspace gas analysis.

Developed by Gasporox in collaboration with its technology partners, this laser sensor technology is widely used in demanding industries such as pharmaceuticals, petrochemicals, and energy.

Gasporox’s laser-based headspace analysis has been successfully deployed for over a decade in pharmaceutical manufacturing. It is integrated into fully automated inspection systems and benchtop instruments for 100% in-line and laboratory testing of vials, ampoules, and other parenteral packaging formats. The performance and robustness of the system have been validated through extensive real-world use.

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