Client Overview
We were contacted by a major bioprocessing facility in Europe specialising in small-batch production of bulk drug substances. This plant supports a high-value specialty pipeline focused on oncology and immunology and relies on single-use (SU) systems to maintain flexibility and sterility in its processes.
Project Objectives
The client required a secure and reusable solution for transporting 1L and 2L SU bags,complete with tubing, within their facility. The solution had to:
- Withstand freezing to -80°C
- Maintain the integrity of the bag and tubing during freeze/thaw cycles
- Be sanitisable and suitable for repeated use
Our Solution
Leveraging our deep experience in stainless steel design for SU systems, we proposed a tailored solution through our Strikebox system. To guide the process, we provided the client with our technical discovery questionnaire, which collected detailed information including:
- 2D Bag capacity and dimensions
- Freezing and thawing requirements
- Sterilisation expectations (post-use cleaning and preferred method)
- Tubing configurations and spatial allowances
These insights enabled us to develop an initial design that addressed all functional and environmental demands from the start.
Process & Collaboration
Key areas we covered in the Strikebox Discovery Questionnaire:
- Bag capacity, size, and tubing layout
- Thermal exposure (e.g., freezing/thawing cycles)
- Reusability and cleaning expectations
- Mobility and equipment integration needs
Once the completed form was returned, we scheduled a collaborative TEAMS call with the client’s technical and operations teams to refine priorities and align on the solution scope. This collaborative step is core to our approach, ensuring rapid alignment and fewer design iterations.
The client valued the structured and efficient process, which eliminated ambiguity and allowed our design team to move quickly into prototyping.
Challenges Overcome
A central design challenge was the need to protect the tubing without immobilising it. The Strikebox case was therefore custom designed to:
- Match the bag’s exact profile with allowances for tubing space
- Avoid tubing supports inside the cavity, to accommodate natural movement during freeze/thaw
- Be fully reusable and easy to sterilise between uses
This design ensured the contents remained safe and undamaged while maintaining process integrity.
Sustainability Considerations
Sustainability played a key role in material selection. The stainless steel case:
- Eliminated the need for disposable packaging
- Was easy to clean and reuse
- Provided a long lifecycle solution with reduced waste and improved carbon efficiency.
- Cases are a listed product on the Strikebox Take-Back Scheme eco initiative.
Results & Impact
Following initial prototyping and testing, the final Strikebox system was delivered with only minimal tweaks. The client reported:
- 42% cost savings in packaging over the fiscal year
- Zero product loss during internal transport
- A smoother, validated workflow now integrated into regular operations
Customer Feedback
“Strikebox delivered exactly what we needed, a durable, reusable, and compliant solution tailored to our process. The structured approach made it fast and easy to implement.”
— Client Operations Lead
Featured Tool: Strikebox Discovery Questionnaire
This project showcased the value of our structured design process. By asking the right questions upfront, from bag size and temperature requirements to sterilisation needs and mobility preferences, we ensured a fit-for-purpose solution was delivered quickly and effectively.
