Integrated One-Stop OEM: From Container Manufacturing to Reagent Formulation and Filling
Building on our long-standing expertise in plastic container design and manufacturing, Aska Company has integrated advanced production capabilities for liquid filling and assembly within Class 100 controlled cleanroom environments.
This allows us to supply high-quality industrial diagnostic reagents produced through reliable, aseptic dispensing processes.
We offer comprehensive, one-stop OEM services for industrial testing reagents
—covering everything from custom container design and engineering modifications
to third-party sterilization management for materials and finished products.
Liquid Formulation and Sterilization
Formulation and Sterilization Processes for Testing Reagents
Raw Material Weighing and Reagent Preparation
Target pure water and powder reagents are precisely weighed and mixed using magnetic stirrers until homogenous.
Quality control is maintained throughout using pH meters, with adjustments made as needed.
High-Pressure Steam Sterilization via Autoclave
Formulated testing reagents and handling equipment are subjected to high-pressure steam sterilization in autoclaves prior to use, ensuring reliable aseptic dispensing operations.
Fully Automated Filling and Assembly
Automated filling, product assembly, and integrated visual inspection system options.
Automated Dispensing and Assembly Operations
By implementing custom-engineered clean booths within our cleanroom facilities, we maintain a controlled production environment rated at Class 100 or better.
Aseptic dispensing integrity is sustained through continuous environmental monitoring—including real-time particle counts and airborne microbe testing—combined with stringent operating procedures and controlled cleanroom maintenance.
Example of Automated Filling Equipment
Manual Filling
Manual Dispensing for Low-Volume Lots
Manual Filling and Capping Operations
Offline operations are conducted within a dedicated Class 1,000 cleanroom equipped with dedicated clean units.
To achieve Class 100 or better conditions during manual filling, work is performed inside clean benches to support aseptic dispensing.
This compact setup enables flexible manufacturing, adapting easily to specific lot size requirements.
Operations Inside a Clean Bench
・Container assembly and capping
・Reagent filling via precision manual dispensers (mechanically controlled volume dosing)
Environmental Testing and Facility Control
Stringent monitoring and management protocols to mitigate personnel and material contamination.
Access Protocols: Small-Batch Production Lab
Access to both the automated clean booth and the dedicated Small-Batch Production Lab requires strict compliance with a two-stage gowning and entry protocol. Personnel must don sterile masks, gloves, and specialized cleanroom garments to prevent foreign contaminants from entering the environment.
These procedures ensure cleanroom integrity and sustain high-precision aseptic dispensing standards.
Small-Batch Production Lab
Environmental Microbiological Control and Monitoring
Cleanroom air quality is monitored in real time using automated particle counters.
In addition, airborne microbe testing is conducted periodically to verify and sustain aseptic environment conditions.
浮遊菌管理対象
| Target Microorganisms | Culture Media |
| Coliforms (E. coli) | Desoxycholate Agar (DC) |
| General Bacteria | Desoxycholate Agar (DC) |
| Fungi & Yeasts | Potato Dextrose Agar (PDA) |
Testing Services for Product Quality Control
We offer comprehensive product testing services, including growth promotion and inhibition testing for target microorganisms, liquid sterility testing (incubation), and pH measurement.
Leveraging our long-standing container engineering expertise, we also recommend structural quality control evaluations—such as cap opening torque measurement and hermetic seal integrity testing—tailored to specific container design characteristics.
Additional customized inspection protocols can be accommodated upon request.
Subcontracted Sterilization Services
Subcontracted sterilization services are available for incoming production materials
and finished products through our vetted partner network.
Ethylene Oxide Gas (EOG) Sterilization
Plastics and production materials undergo pre-use sterilization.
To minimize residual gas levels and maintain product integrity, post-sterilization quarantine and aeration management are maintained for approximately two weeks.
Gamma Radiation Sterilization
Gamma irradiation processing is managed via our partner network, accommodating lot volumes ranging from single cases to full pallets.
Aska Company provides flexible packaging specifications and shipping formats to align with customer distribution requirements.