Supporting Roche with Advanced Testing and Seamless Service Integration

For our valued customer Roche, we delivered a state-of-the-art Bombing Station equipped with a NEO HSX system, specifically engineered to perform critical vial integrity testing under both high overpressure and underpressure conditions.

But what exactly is a bombing station for accelerated air ingress? In pharmaceutical manufacturing, verifying Container Closure Integrity (CCI) is vital. By combining a physical pressure chamber (the bombing station) with laser-based Headspace Analysis (HSA) testing, we create a sensitive, non-destructive leak detection method. Glass vials are placed inside the chamber and exposed to elevated pressure environments using air or a specific tracer gas. This process artificially accelerates the ingress of gas through even the most microscopic defects or leaks. Following this exposure phase, the NEO HSX system analyzes the internal gas composition of the headspace. If any gas ingress is detected, a leak is identified, ensuring that only perfectly sealed, safe vials reach patients.

When selecting their setup, Roche was thoroughly convinced by the high-quality mechanics of the WILCO equipment. The robust, stable engineering guarantees maximum reliability over years of intensive laboratory or production use.

Hardware, however, is only half of the equation. Roche’s operating teams were equally impressed by our MAVIS software. MAVIS is highly intuitive and user-friendly, translating complex, high-precision scientific testing parameters into straightforward, easy-to-manage workflows for everyday operations.

After the system had been successfully operating in one facility for an extended period, Roche initiated an internal infrastructure move. Our WILCO Customer Service department was commissioned with the task of managing and realizing the relocation of this highly sensitive setup from one location to the next.

Relocating validated pharmaceutical testing systems requires rigorous precision to preserve compliance standards. Our service engineers deployed a meticulous, multi-step process:

Pre-Calibration
Complete mapping and documentation of the machine’s performance parameters prior to the shutdown.

Decommissioning & Transport
Safely disconnecting electricity and compressed air infrastructure, followed by secure physical transit between buildings.

Assembly & Re-commissioning
Mechanical re-assembly and precision installation at the new site.

Re-Qualification Testing
Comprehensive validation protocols to ensure strict pharmaceutical regulatory requirements were fully met.

Re-Calibration
Final testing to guarantee that the machine’s calibration values perfectly matched the identical parameters documented before the move.

No complex system move is completely without surprises. During the commissioning stage at the new location, the team discovered a significant challenge: the local facility’s compressed air supply was too weak to sustain the machine's strict operational limits.

Rather than allowing this bottleneck to cause costly project delays, the WILCO service specialists immediately engineered a creative workaround solution. This idea was presented directly to the Roche team on the ground, who was able to implement it swiftly. Thanks to this technical agility and proactive mindset, the problem was solved without compromising the project timeline.

Our annual service maintenance is consistently handled with professionalism. The WILCO technicians arrive thoroughly prepared, execute their work competently, and proactively offer valuable optimization tips and suggestions for our operations. Communication with WILCO is always transparent, smooth, and efficient.  F. Hoffmann-La Roche Ltd

At its core, this project’s success is a testament to an exemplary corporate partnership. The collaboration among WILCO, Roche, and external third-party partners was seamless. Every milestone was achieved working hand-in-hand.

A vital component of this smooth delivery was communication: the primary contact person at Roche was consistently reachable, highly proactive, and provided excellent on-site support. Following the successful re-qualification, a final close-out discussion took place to wrap up the project on an exceptionally positive note. This project reinforces that when technical expertise is combined with open, transparent collaboration, any challenge can be successfully mastered.