Automated Medical Device Production: Nasaleze
How Nasaleze scaled from 1,000 to 30,000 bottles per day using Cap Coder’s automated filling and capping machines for medical device production.
Nasaleze is a UK-based, family-run healthcare company delivering effective allergy prevention products. Their powder nasal spray blocks dust, pollen and can provide added protection from airborne viruses. Their powdered blockers are certified as a medical device with FDA approval, ISO 13485, and ISO 9001 compliance.
Run by a small, dedicated team, Nasaleze faced a critical challenge. Production was limited to 1,000 bottles per day, with six staff manually filling and capping each bottle by hand. Scaling operations while maintaining consistency and compliance was essential. Partnering with Cap Coder transformed their production, enabling higher output, improved efficiency, and reliable quality, all while staying true to their dedicated, customer-focused approach.
The Challenges of Manual Production
Previous experiences with other machinery suppliers had left Nasaleze cautious, reinforcing the need for a partner they could truly trust, one that offered reliable, precise, and flexible automation with hands-on support. As the business grew, manual production could no longer keep pace. Handling powder nasal spray by hand created major bottlenecks, the process was slow, labour-intensive, and prone to inconsistencies. Even small errors in filling or capping posed a risk to product safety, an unacceptable compromise for a certified medical device. It was clear that Nasaleze needed a practical, scalable solution to take their production to the next level.
Priorities for Scaling Production
When exploring automation, Nasaleze focused on three priorities:
- Reliability: Machinery had to deliver consistent, repeatable results.
- Precision: The system needed to handle bottles and caps with accuracy and reject any units that didn’t meet standards.
- Flexibility: Machines had to adapt to Nasaleze’s specific product requirements and accommodate future upgrades.
Cash flow management was also important. As a small, family-run business, flexible payment terms would allow them to invest in smart, reliable automation without straining resources.
The Cap Coder Solution
Cap Coder delivered a fully customised solution built around Nasaleze’s needs. Between 2006 and 2024, the company invested in three machines, two CC1160 Monoblocs and one CC1160 Twin Head, to support their growing production. From the very start, the process was seamless. Nasaleze sent over product samples, and Cap Coder’s engineers took care of the rest, designing detailed drawings and precise machine configurations tailored to the exact dimensions and requirements of their powder nasal spray bottles.
The Machines
The CC1160 Monobloc machines handle complex, multi-component products. Empty bottles are automatically fed into the system, sterilised with UV light, and filled via a high-precision peristaltic pump. For Nasaleze, every component undergoes rigorous safety and quality testing, including leach testing, making precision and accuracy in the filling and capping process critical. Confocal vision sensors check fill levels, plugs are inserted and validated, and caps are applied with torque monitoring. Any bottle failing validation is automatically rejected, ensuring full compliance and consistent quality.
The CC1160 Twin Head machine delivers high-speed production at 60 bottles per minute. This allowed Nasaleze to scale to over 30,000 bottles per day, without compromising accuracy. Compact and efficient, it’s perfect for small teams while providing industrial-level output. Integral bowl feeders for caps ensure smooth, continuous operation. Cap Coder also provides upgrades and ongoing support. Even the 2006 machine was easily modified to match the specifications their 2017 model, demonstrating the Cap Coder commitment to expertise and long-term partnerships.
Transformative Results
The results were dramatic:
- Production Boost: Production jumped from 1,000 to over 30,000 bottles per day, transforming output from a slow, manual process into a high-speed, precision-driven operation.
- Workload Freed Up: Staff workload decreased, giving the team time and resources to focus on other areas of the business while Cap Coder machines handled the heavy lifting.
- Reliable Consistency: Consistency and quality improved, with fail-safe systems and automatic rejection of any non-compliant bottles, ensuring every unit met strict medical device standards.
- Smooth Integration: Integration was seamless, with quick setup and minimal disruption, allowing Nasaleze to scale production without interrupting ongoing operations. The results were dramatic:
For a medical device, these improvements are essential. Nasaleze can now meet international demand, including new markets like Canada, while maintaining the highest standards.
Testimonial
“Cap Coder’s engineers combine technical expertise with practical, hands-on support. Their family-run, collaborative approach aligns naturally with Nasaleze’s values, turning complex automation challenges into straightforward, successful solutions!”
What Makes Cap Coder Stand Out
Nasaleze describes their experience with Cap Coder as worlds apart when compared to previous suppliers. The team is responsive, solution-focused, and able to adapt machinery to evolving requirements. Even when managing operations from Canada, Simon found communication seamless, with expert guidance available whenever needed.
Cap Coder: Your Expert Partner in Filling and Capping Solutions
Nasaleze’s transformation showcases the power of expert automation in medical device production. With Cap Coder, the company scaled from a small manual operation to a high-output automated line, producing over 30,000 bottles per day with reliable quality and minimal manual input.
Cap Coder’s precision engineering, bespoke solutions, and expert support provide more than machines, they deliver confidence. For companies producing powder products, multi-component medical devices, or other healthcare items, Nasaleze’s experience demonstrates the impact of partnering with a trusted expert. Cap Coder ensures operations run efficiently, reliably, and at the highest standards, making growth not just achievable, but sustainable.
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