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The pharmaceutical industry is experiencing a period of unprecedented transformation, characterised by the adoption of advanced technologies and the automation of production processes. In this scenario, LAST Technology stands out globally in the design and production of process equipment for the pharmaceutical and biopharmaceutical sectors and for research laboratories. The company’s mission is clear: to develop cutting-edge solutions for infection prevention, actively contributing to the protection of public health. We talked about it with Massimo Castellarin, President and CEO of LAST Technology.

The development of LAST Technology is firmly linked to research and innovation. How so?
Research and development are the pillars on which LAST Technology bases its growth strategy. The company actively collaborates with the main pharmaceutical and biopharmaceutical industries, developing customised solutions to meet the unmet and increasingly complex needs of the market. LAST Technology’s innovative approach translates into customised machinery, equipped with advanced automation and integrated technologies, capable of combining increasingly complex processes. One of the distinctive elements of the R&D strategy is the integration of commercial components and software that guarantees reliability, flexibility in the development of tailor-made solutions and remote control of equipment via centralised servers, tablets and smartphones. This approach allows optimising production processes and minimising intervention and maintenance times, increasing the overall reliability of the machines.

What are the latest innovations you offer?
LAST Technology is constantly engaged in the development of new technological solutions to improve pharmaceutical production processes. Among the main innovations introduced by the company we can mention: the use of a ketone (acetone) to remove the most resistant dirt from pharmaceutical active ingredients; ‘combo’ solutions that integrate washing and sterilisation in a single process; combined sterilisation systems using superheated water and steam for solids and liquids; low temperature sterilisation with ethylene oxide or hydrogen peroxide for heat-sensitive components; ATEX hot air drying machines for potentially explosive solid products. LAST Technology is a reliable and competent partner in the evolution towards the ‘automatic factory’, an increasingly widespread model in the pharmaceutical industry. In this sense, the company has developed innovative software based on market technologies and widely recognised communication protocols. This allows the integration of all LAST Technology process machines within the company domain, ensuring greater efficiency and connectivity.

Innovation in the proposal, but also in the optimisation of internal production processes.
LAST Technology has implemented an advanced computerised system to improve production efficiency and order management, making the management of the product life cycle more effective and optimised, from the Concept Design phase to C&Q. Thanks to the adoption of a PLM (Product Lifecycle Management) software platform, the company is able to interconnect all business functions, from product conception to marketing. The integration of PLM has reduced order management times by 20-30%, improving collaboration between the various departments. The use of mobile computer workstations in the assembly and testing areas allows internal staff and visiting customers to quickly access the technical documentation of the job order. This has significantly improved business efficiency, reducing time and enhancing the control of integrated processes in quality management. The project is part of the company’s computerisation strategy, supporting growth through the integration of Business Process Management, company know-how, data and documents.

Sustainability is an important value for you. What initiatives are you undertaking?
LAST Technology’s commitment to sustainability is realised through a business model based on the creation of shared value. The company has aligned its strategy with the United Nations Sustainable Development Goals (SDGs), adopting practices aimed at reducing environmental impact and promoting corporate social responsibility. The main sustainability initiatives include reducing emissions by 50% by 2024 thanks to energy efficiency and the installation of a 515 kWh photovoltaic system; implementing carbon neutrality policies by 2030; promoting an inclusive and stimulating work environment, enhancing the talent and creativity of employees. Knowledge of stakeholder needs and market dynamics also guides us in developing collaborations beyond sector boundaries, integrating economic growth, social well-being and sustainability. In doing so, we not only pursue our corporate objectives, but also actively contribute to collective progress. LAST Technology, in line with its Sustainability Policy, today takes a further step in the process of building shared value by obtaining the Silver Medal rating from EcoVadis.

A global reference
LAST Technology looks to the future with a clear strategy of innovation and internationalisation. The company aims to become a global leader in the sector, combining advanced technologies and process automation, according to the philosophy of ‘thinking globally and acting locally’. In this sense, Artificial Intelligence will play a key role in the company’s evolution.

Alsystems’ journey began in San Casciano Val di Pesa (Florence – Italy) in 1991, when the company started to develop automation systems for various types of machinery as a pure third-party supplier. The Florentine company offered a wide range of solutions for many different industrial sectors, from filling and closing lines for the pharmaceutical and cosmetics industries to other sectors. «For over 25 years – CEO Goffredo Ruffini told us – our machines have handled a wide range of products: gels, creams, granules, powders for exams and diagnostics, infusion and ophthalmic liquids, syrups, nasal and oral sprays, homeopathic products and disinfectants. We offer filling and capping machines or complete turnkey systems specifically for the pharmaceutical, biomedical and parapharmaceutical sectors. We have about ten models that differ in terms of characteristics, operating speed and type of bottles and our strong point is that we carry out every phase internally, from design to testing, so as to guarantee our machines for 24 months. Customisation is a key word. Our strong point is the ability to design and build each machine around the real needs of the customer, right from the first contact. This approach allows us to provide solutions that perfectly match production needs and to establish an ongoing relationship with users, before the sale and throughout all the subsequent phases up to after-sales, which is an integral part of our way of working». Having an in-house technical department allows the company to follow every detail of the project, guaranteeing full control over quality. The company can therefore offer a 24-month warranty on all its machines. A clear sign of trust and reliability that for Alsystems is a natural choice, the result of in-depth knowledge of the components produced and how they work.

The advantage of versatility

From the 90s to the present day, Alsystems has grown to a workforce of 20 and a production capacity that varies according to the type and size of the machines, on average 15-18 units every year. If customisation and quality are among the company’s outstanding prerogatives, versatility and reliability are what allow its models to stand out and «effectively cover a wide variety of sectors», Ruffini observed. «If I had to identify a star of the Alsystems portfolio, I would choose the Pegasus capping and filling machine. It’s aimed at the chemical-pharmaceutical and parapharmaceutical industries, but can be adapted to a wide range of applications and has been developed to handle bottles with capacities ranging from the smallest to volumes of one litre. In the single index version it can produce up to 3,000 pieces per hour; in the double index version it can produce up to 6,000 pieces per hour. Therefore it is suitable for different types of job, to meet a wide range of production requirements». The company also operates in the field of high-speed rotary presses for small formats with an output of up to 240 pieces per minute with the Hercules model. This is highly appreciated in the food supplement sector because it is equipped with sensors, volumetric dosing systems and, on request, cameras for quality control. It can handle bottles, test tubes, small bottles, with closures ranging from screw caps to droppers and pipettes, and competes well with the competition by focusing on technological quality. «With its multiple filling system – explained the CEO – Hercules has won acclaim in Italy and abroad».

The robot to come

Alsystems is also an export success, given that its machines can be found all over Europe, as well as in Mediterranean countries such as Egypt, Tunisia, Jordan and some Asian countries, thanks to a network of dedicated agents and representatives. At the same time, investments in R&D continue. «Currently – the interviewee said – the idea is to introduce a new generation of robots for movement management and machine enslavement. A series of targeted tests are underway with the aim of helping us understand how they can be used in practice. The fine tuning should be completed by the end of the year and from then on we will try to study the needs of customers to understand which ones might be interested in it. Innovation could find a place among the producers of parapharmaceuticals and pharmaceuticals that together represent more than half of Alsystems’ total turnover. Another significant slice of sales is in the chemical sector, where the Auriga series for large formats has proven its worth. Together with the products, the supplier is also very keen to offer services, which are also made possible thanks to the push towards digitalisation. «All our machines – explains Ruffini – can be connected to a network for remote assistance directly from our headquarters. For on-site maintenance technicians and end users, remote support is an advantage and we guarantee it by default at no additional cost. In addition, all machines can be equipped with specific modules for interconnection to ERPs to monitor batches and orders together with the progress of work for reporting purposes or to receive indications of work batches directly from the management system». Finally, a certain amount of attention is paid to reducing consumption. «We are conducting studies and analyses – concludes Ruffini – although further reducing energy requirements on engines that do not exceed 2 kW is not easy. Although Alsystems machines are by nature energy efficient, we always try to integrate them with engines with the highest possible performance».

Pegasus and Hercules

Pegasus is a versatile rotary machine for filling and capping. It can handle containers from 1 to 1,000 ml, with an hourly production of 500 to 6,000 pieces. It can handle containers with a maximum diameter of 82 mm and a maximum output of 100 pieces per minute. It has a stainless steel frame and is highly customisable from a technical point of view. The high-performance Hercules rotary machine, on the other hand, has a production speed of 240 pieces per minute with advanced volumetric dosing and quality control functions. It adapts to a wide variety of bottles and capping systems and is equipped with different types of sensors to ensure high-quality production in every area or phase of work.