Skip to content

Aseptic Fill & Finish (AFF)

Aseptic Fill & Finish – The Critical Step in Sterile Manufacturing

We support biotech and pharmaceutical innovators with compliant, scalable aseptic filling solutions – from early clinical batches to global commercial supply.

  • Complex Modalities: Expert AFF of sensitive biologics and advanced therapies.
  • End-to-End Capability: From clinical batches to high-volume commercial.
  • Highest Standards: Strong regulatory track record (FDA/EMA and others).
  • Secured Capacity: Multiple filling lines to support growth & business continuity.

We deliver excellence

Why choose CordenPharma?

Selecting the right CDMO partner for your sterile injectable manufacturing program is a strategic decision. With over 25 years of experience in aseptic processing, CordenPharma combines technical precision with global regulatory expertise. We currently deliver commercial injectable drug products to over 110 markets worldwide – ensuring your complex modalities reach patients safely and on time.

Expertise in Complex Modalities

Leverage our specialized experience in sensitive formulations. Our experts in aseptic fill & finish for Peptides, Oligonucleotides, Biologics (mAbs), and Lipid Nanoparticles (LNPs) tailor processes to stability and viscosity needs, ensuring integrity from formulation to finish.

Impeccable Compliance & Quality

Our cGMP sterile manufacturing site is regularly and successfully inspected by leading global authorities, including the FDA, EMA (AIFA), ANVISA, and TGA. With strict adherence to EU GMP Annex 1 and a robust Contamination Control Strategy (CCS), we provide high sterility assurance and confidence in every batch.

Flexible & Scalable Capacity

From clinical start-up to commercial launch, our facility scales with your project. We offer multiple aseptic filling lines for Pre-Filled Syringes (PFS), vials, and cartridges, supporting everything from small clinical batches to high-volume commercial supply. Capabilities include lyophilization and customer-dedicated line options to help secure long-term supply.

Our Aseptic Fill & Finish Approach

Your CDMO Partner for Scalable Aseptic Fill & Finish

From clinical agility to commercial certainty.

Navigating the journey from a promising clinical candidate to a global product requires more than just capacity – it demands continuity. Our state-of-the-art Sterile Injectables facility in Caponago (Italy) serves as your single CDMO partner for the entire lifecycle. By keeping your product under one roof, we eliminate the risks of technology transfer, ensuring a seamless transition from clinical manufacturing to global commercial supply.

What we offer you:

Expertise in Complex Modalities

We don’t just fill standard liquids. We specialize in the aseptic fill & finish of Peptides, Oligonucleotides, LNPs, and Biologics (mAbs), offering both liquid and lyophilized dosage forms. Whether utilizing Pre-Filled Syringes (PFS), vials, or cartridges, our processes are optimized to meet your unique requirements.

Secured & Scalable Capacity

Supply continuity is our priority. With an annual capacity exceeding 200 million units, we offer flexible scale up from small-scale clinical batches to high-speed commercial manufacturing lines by adapting to your demand forecast, without compromising on lead times.

Cutting-Edge Aseptic Technology

Your product benefits from the latest advancements in aseptic processing, including robotic filling lines, Nest & Tub ReadytoFill (RTF) concepts, and SingleUse Systems (SUS) designed to minimize contamination risks. Stainless steel equipment is also available when required. Sensitive APIs are handled in glovebox‑equipped compounding areas under strictly controlled environments.

Analytical Services

Our teams provide full analytical support alongside formulation and process development, helping you build reliable, wellcharacterized methods that ensure your injectable product performs consistently.

Comprehensive Regulatory & Documentation Support

Navigating global regulatory requirements can be complex. We simplify your journey with hands-on support for dossier preparation, technical documentation, and prompt, expert responses to health authority questions, helping you accelerate approvals and market access.

Comprehensive Inspection & Packaging

Quality extends to the final presentation for your patients. We offer manual and automated visual inspection and flexible secondary packaging solutions – including serialization and aggregation – to meet global traceability requirements.

Our Specialized Aseptic Fill & Finish Services

World‑class aseptic fill & finish capabilities spanning diverse molecule types and the complex modalities required for modern therapies.

 

Peptides

Peptides are short chains of amino acids that act as highly specific biological messengers in the body. Because of their precision, potency, and favorable safety profiles, they have become one of the fastest‑growing classes of therapeutic molecules used in metabolic diseases, oncology, infectious diseases, and cosmetic applications.

CordenPharma is a global leader in peptide drug substance development and manufacturing. With 130 years of cumulative peptide expertise, the company provides end‑to‑end capabilities including SPPS & LPPS synthesis, Tag-Assisted Peptide Synthesis (TAPS), oral peptide manufacturing, complex peptide conjugations, HPLC purification, precipitation, analytical development, scale‑up expertise, and peptide-injectable fill & finish. Discover our Peptides platform.

Oligonucleotides

Oligonucleotides are short chains of nucleotides, the basic building blocks of DNA and RNA. They typically range from about 15–30 nucleotides, though they can be shorter or longer depending on their application. Their defining feature is their ability to bind sequence, specifically to complementary DNA or RNA, which makes them powerful tools in both research and therapeutics.

CordenPharma delivers comprehensive oligonucleotide capabilities, combining GMP oligonucleotide manufacturing with state-of-the-art aseptic fill & finish, to provide true end-to-end support from API development through final drug product.

Proteins

Proteins are large, complex molecules made up of long chains of amino acids. They play essential roles in all living organisms, from building tissues and enzymes to driving immune responses and cellular communication. Their structure determines their function, and because they are biologically active, they often require careful handling, controlled environments, and specialized formulation when developed as injectable therapies.

CordenPharma formulates and fills proteins, including antibodies and fragments (ABs, fABs), as part of our injectable development capabilities.

Monoclonal Antibodies

Monoclonal antibodies (mAbs) are lab‑made proteins designed to mimic the way the immune system naturally identifies and neutralizes harmful targets. They are created by producing many identical copies (“clones”) of one specific antibody that binds to a single, precisely defined antigen. This makes mAbs highly targeted tools used widely in medicine, including treatments for cancer, autoimmune diseases, infections, inflammatory conditions, and more.

CordenPharma offers the filling of injectables containing monoclonal antibodies.

Highly Potent & Oncology

High potency typically describes active ingredients or drug products that are biologically active at extremely low doses and therefore require special containment and handling measures for operator safety. Highly potent compounds are routinely used in oncology because many cancer treatments act at very small therapeutic doses with targeted, powerful effects.

CordenPharma provides fully integrated, end-to-end Highly Potent & Oncology services spanning the development & manufacturing of APIs and Drug Products, including aseptic filling and packaging. Learn more about our Highly Potent APIs & Oral Solid Drug Product Manufacturing.

Advanced Therapy Medicinal Products

Advanced Therapy Medicinal Products (ATMPs) are a class of innovative medicines for human use that are based on genes, tissues, or cells. They represent some of the most advanced biomedical technologies and often offer treatment options for diseases that previously had no cure.

CordenPharma’s injectables filling services and LNP (Lipid Nanoparticle) capabilities directly support key ATMP-related therapeutic classes, such as mRNA, oligonucleotides, plasmid DNA (via partnerships), and other genetic payloads. Discover our Lipid Nanoparticle (LNP) formulation development & GMP manufacturing services.

Small Molecules

Small molecules are low molecular weight drug substances, typically below ~900 Da, that can enter cells easily and interact with biological targets such as enzymes or receptors. They are usually chemically synthesized, stable, and most often administered orally, but they can also be formulated as sterile injectables, nasal sprays, liquids, and other dosage forms.

CordenPharma offers extensive capabilities across the full value chain, from small molecule API development & manufacturing through final drug product, including aseptic fill & finish when the small molecule requires a sterile presentation.

Discover our Oral Solid Dose (OSD) small molecule manufacturing capabilities.

Aseptic Manufacturing Capabilities

State-of-the-Art Infrastructure

  • 3 Aseptic Filling Lines: Including Robotized Open RABS (Restricted Access Barrier Systems) for maximum sterility assurance.
  • Future-Ready Expansion: Installation of 2 new isolator lines (1 high-speed PFS filling line for late stage & commercial and 1 flexible combo line for phase 1-3, small-scale commercial (operational mid-2027 & 2028))
  • Ready-to-Fill (RTF): Fully compatible with Nest & Tub formats for efficient aseptic processing.

Flexible Format Range

  • Pre-Filled Syringes (PFS): 1 ml to 10 ml (fill volumes starting from 0.5 ml).
  • Vials: Standard sizes from 2R to 20R.
  • Cartridges: Dedicated filling for 3 ml formats.
  • Inspection: Manual & fully automatic inspection lines for both PFS and vials.

 

Process Adaptability

  • Batch Sizes: Flexible range from 10 L to 300 L .
  • Compounding: Choice of Stainless Steel vessels or Single-Use Systems (Disposable) to eliminate contamination.
  • Pumps: Rotational or Peristaltic pumps (gentle handling for shear-sensitive biologics).
  • Lyophilization: Integrated freeze-dryer for stable lyophilized vials.

Our Process

Your Path to Reliable Aseptic Fill & Finish

The critical steps to robust aseptic manufacturing.

We guide you through every critical milestone. Our standardized yet flexible workflow ensures your complex modalities are handled with maximum safety, compliance, and efficiency.

Next Process
Next Process
Next Process
Next Process
Next Process
Next Process
Next Process

Analytical Transfer & Development

Foundation for Success:

We work closely with you to ensure all analytical methods for product testing are smoothly transferred, or developed, and validated. This guarantees reliable, regulatory-compliant testing, laying the foundation for robust quality control throughout your project.


Packaging & Logistics, Visual Inspection

Ensuring End‑to‑End Integrity and Traceability

Integrated secondary packaging and pharmaceutical serialization track & trace.

Your sterile product demands protection until the point of care. We offer end-to-end parenteral packaging services, ensuring rigorous visual inspection, compliant pharma serialization, and secure global distribution for your clinical and commercial supplies.

Precision Quality Control

We offer two options of visual inspection to ensure your products are compliant with established specifications.

Automated: High-speed inspection using Antares Vision (for Vials) and Seidenader technology (for PFS).

Manual: Qualified operators for small batches or complex visual characteristics.

Versatile Configurations

Benefit from six fully automated packaging lines, offering both individual and multi-pack configurations for vials, PFS, ampoules, and cartridges. This flexibility ensures your products are packaged exactly as needed, whether for commercial launch or clinical trials.

Global Track & Trace

Security is non-negotiable. Our lines feature advanced serialization and aggregation technology fully compliant with EU and US regulations, ensuring complete traceability across your global supply chain.

Dedicated Support

We manage the complexity of clinical supply chains. Our dedicated area for Clinical Trial Packaging offers labeling, kit management, and distribution support, ensuring your investigational products reach the site on time and according to your unique trial requirements.

Technologies

Advanced Aseptic Technologies & Infrastructure

Purpose-built for precision, sterility, and product stability.

We employ a diverse range of aseptic processing technologies to match the specific needs of your molecule. From flexible clinical setups to high-speed commercial lines, our infrastructure ensures compliance with the latest Annex 1 regulations.

Sterility Assurance & Barrier Systems

We offer the right containment strategy for your product’s phase and potency:

  • Open RABS (Restricted Access Barrier Systems): A more economical and less complex alternative offering operational flexibility and continuity for clinical and small-scale commercial batches.
  • Isolator Technology: The gold standard for aseptic filling. Our roadmap includes state-of-the-art isolator lines (operational mid-2027) to provide maximum contamination control for flexible clinical and high-volume commercial supply.

Precision Dosing for Sensitive Biologics

Protecting your molecule’s structure is our priority. We utilize:

  • Peristaltic Pumps: Ideal for shear-sensitive biologics and monoclonal antibodies, preventing foaming and degradation during the fill.
  • Mechanical Piston Pumps: Ensuring high-speed precision for formulations, including viscous, for clinical and large commercial parenteral manufacturing campaigns.

Advanced Container Handling

  • Ready-to-Fill (RTF): We utilize Nest & Tub technology for Pre-Filled Syringes, vials, and cartridges. This pre-sterilized format eliminates depyrogenation and washing steps, accelerating your time-to-market.
  • Vacuum Stoppering: Essential for oxygen-sensitive products. This technology reduces headspace in the syringe, enhancing the stability of complex injectables.

Complex Formulation & Stabilization

  • Single-Use Systems: We employ disposable formulation technologies to eliminate cross-contamination risks and bypass time-consuming cleaning validations – crucial for highly potent APIs.
  • Lyophilization: For unstable formulations, our integrated lyophilization capabilities (freeze-drying) convert liquid solutions into stable lyophilized vials, extending shelf life for global distribution. Learn more about our lyophilization expertise.

Our Manufacturing Sites

CordenPharma Caponago

CordenPharma Caponago (IT) is a cGMP manufacturer of a wide range of sterile liquid dosage forms for injectable use, with specialized expertise in aseptic fill and finish, terminal sterilization and Lipid Nanoparticle (LNP) manufacturing.

The site has a full range of capabilities including formulation, process and purification development, cGMP manufacturing, clinical trials management, secondary packaging & pharma logistics.

Find out more

Global Quality & Compliance Standards

Built-in Quality & Regulatory Confidence

From initial formulation to final quality release, we uphold scientific rigor and strict regulatory compliance. Our global quality network ensures your sterile product meets the highest standards for safety and efficacy.

A Proven Partner – FDA & EMA Compliance

Navigate the regulatory landscape with confidence. Our sterile manufacturing facility in Caponago, Italy maintains an exceptional inspection history:

  • Global Approvals: Successfully audited by FDA, EMA, ANVISA, and several Ministries of Health.
  • Impeccable Record: No Warning Letters or GMP Non-Compliance Statements since joining CordenPharma in 2009.
  • Risk Mitigation: A mature Quality Management System (QMS) designed to secure your supply chain against regulatory disruptions.

Quality by Design (QbD) – Proactive Quality Strategy

We don’t just inspect quality; we design it.

  • QbD Approach: We apply Quality by Design (QbD) principles to define Critical Quality Attributes (CQAs) early in the process.
  • Data-Driven CMC: Our teams prepare robust CMC documentation (Chemistry, Manufacturing, and Controls) to support your IND / IMPD or NDA / MAA submissions, minimizing questions from health authorities.

FAQs

Aseptic Fill & Finish Frequently Asked Questions

Explore answers to common questions about our sterile manufacturing services, capabilities, and technologies.

What is Aseptic Fill & Finish?

Aseptic Fill & Finish is the final, critical step in sterile drug manufacturing and lies at the heart of aseptic processing. Because sensitive modalities like peptides, oligonucleotides, biologics, vaccines and other advanced therapies cannot tolerate terminal sterilization, there is no margin for error. We safeguard your product’s integrity by transferring it into vials, Pre-Filled Syringes (PFS), or cartridges under rigorously controlled conditions – ensuring the highest quality for your patients.

What is the difference between aseptic processing and terminal sterilization?

Terminal sterilization involves sterilizing the final product in its container using heat or radiation. However, sensitive drugs like biologics, peptides, and oligonucleotides, vaccines or other advanced therapies are often heat-labile and would degrade under these conditions. Aseptic processing (or aseptic filling) prevents contamination from the start by filtering the drug product and filling it into pre-sterilized containers (vials, Pre-Filled Syringes (PFS), cartridges) within a sterile environment, ensuring product safety without compromising efficacy.

What types of complex modalities and drug products do you manufacture?

We specialize in the aseptic fill & finish of complex, high-value modalities. This includes Peptides, Oligonucleotides, Small Molecules, Monoclonal Antibodies (mAbs), Biologics, Lipid Nanoparticles (LNPs) for mRNA vaccines, and other Injectables. We handle liquid and lyophilized formulations in vials, Pre-Filled Syringes (PFS), and cartridges.

Do you support both clinical and commercial aseptic manufacturing?

Yes. CordenPharma offers fully integrated end-to-end support. Our facility in Caponago provides flexible capacity for clinical trials (Phase I-III) with small-scale batches, as well as high-volume commercial manufacturing with an annual capacity exceeding 200 million units. We ensure seamless tech transfer as your program scales.

Are your facilities equipped to handle Highly Potent APIs (HPAPIs)?

Yes. We are experts in the safe handling of Highly Potent APIs (HPAPIs) and oncology compounds. Our aseptic filling lines feature dedicated containment strategies capable of handling compounds with Occupational Exposure Bands down to OEB 5 (< 0.1 µg/m³), ensuring full GMP compliance and operator safety.

What is your approach to quality and regulatory compliance?

Our sites operate under a stringent Pharmaceutical Quality System (PQS) compliant with EU GMP Annex 1 and global regulatory standards. We have successfully passed inspections by the FDA, EMA (AIFA), ANVISA, and PMDA. We apply Quality by Design (QbD) principles to ensure products consistently meet predefined quality attributes, based on scientific understanding and robust process control, ultimately providing  robust contamination control and process reliability.

Ready to start your aseptic fill & finish project?

Partner with CordenPharma for your next sterile injectable program.

Whether you need a quote for a clinical batch or a strategic partner for commercial supply, our team is ready to listen. Discuss your specific challenges directly with our platform leadership.

Dr. John Cameron

VP, Global Commercial Head - Injectable Drug Products