Turnkey Inhaler Production Line Handed Over in Thailand
Our engineering team has successfully completed the delivery, installation and commissioning of a complete inhaler assembly and filling machine line at a pharmaceutical manufacturing facility in Thailand. Delivered on a turnkey basis, the project covered equipment design review, factory acceptance testing (FAT), international shipment, on-site mechanical and electrical installation, PLC and recipe configuration, and full performance qualification — allowing the customer to begin commercial production of inhaled drug products on schedule.
Project Overview
The contract was awarded after a competitive technical and commercial evaluation. The factory needed a compact, GMP-compliant line able to run both metered-dose inhaler (MDI) canister filling and inhaler actuator assembly inside a single controlled cleanroom footprint, with fast format changeover between product families.
| Item | Detail |
|---|---|
| Customer | Pharmaceutical manufacturer, Thailand |
| Project type | Turnkey installation and commissioning |
| Core equipment | Inhaler assembly line and propellant filling machine |
| Design capacity | Up to 8,000 inhalers per hour |
| Filling accuracy | Within ±0.5% of target fill weight |
| Compliance | cGMP-aligned design, CE-marked components |
| Deliverables | DQ, IQ, OQ, PQ and FAT/SAT documentation |
Scope of Supply
- Automatic inhaler assembly machine for actuator, cap, canister and dose-counter sub-assemblies
- Rotary propellant filling and crimping machine with inert-gas purging
- In-line leak testing and check-weighing stations
- Vision inspection for label presence, coding and component orientation
- PLC control with HMI, audit trail and 21 CFR Part 11 ready user management
- Validation documentation, spare parts kit and operator training
Installation and Commissioning Process
- Site readiness survey — verification of compressed air, chilled water, HVAC and cleanroom classification before equipment arrival
- Mechanical erection — positioning, leveling and anchoring of the assembly and filling modules
- Electrical and pneumatic integration — control cabinet wiring, sensor calibration and safety interlock validation
- Recipe development — parameter tuning and tooling adjustment for each inhaler format
- Trial runs — dry runs, placebo trials and product trials with sampled weight and dose uniformity checks
- Training and handover — operator and maintenance training, documentation transfer and spare parts handover
Commissioning Results
- The line reached its rated output during the acceptance run, with stable filling accuracy inside the agreed tolerance band
- Leak test and vision inspection stations achieved the specified rejection sensitivity on seeded defect samples
- Format changeover was completed within the target window using quick-release tooling
- No lost-time safety incidents were recorded throughout installation and commissioning
Why Thailand for Inhaler Manufacturing
Thailand has become a regional hub for respiratory and generic drug manufacturing, supported by investment incentives for high-technology medical production and strong demand across Southeast Asia for asthma and COPD therapies. Local manufacturers are increasingly investing in automated inhaler assembly and filling capacity to serve both domestic hospitals and export markets — and reliable, GMP-compliant equipment installation is the first step in that journey.
Planning a Similar Project?
From single machines to complete inhaler assembly and filling lines, our team supports feasibility studies, layout design, FAT/SAT, on-site installation, commissioning and validation documentation. Contact us to discuss your inhaler or respiratory device project and receive a tailored technical proposal.