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Serum Institute of India is the world’s largest vaccine manufacturer with over 1.5 billion doses produced and sold each year. The company is producing 5.000 doses of the covid-19 Covishield vaccine per minute. Fedegari in close collaboration with Serum and ACE Technologies provided an advanced solution for a fully robotized plant without human intervention,  increasing the efficiency of processing and transferring of sterile closures.

Serum dispatches around 11 million vaccine doses in a day and is proudly working on other three covid-19 vaccine candidates developed in partnership with AstraZeneca, Novavax and Codagenix. This means that Serum is ready to manufacture more than 1.5 billion doses of the covid-19 vaccine.

Fedegari Group has recently concluded the installation of a state-of-the-art robotized system for processing pharmaceutical closures at the biotech manufacturing laboratories of Serum Institute of India that are helping to increase the vaccine production capacity of the company.


The project, developed by Fedegari in close collaboration with ACE Technologies and Serum, provides an advanced solution for a fully robotized plant, with the aim of increasing the efficiency of processing and transferring of sterile closures ready-to-use. The system uses a robotic arm that, by connecting to the filling line, allows the aseptic transfer of washed and sterilized closures, neutralizing any risk of external contamination.

After an in-depth analysis of customer needs and an accurate engineering study to improve cost-effectiveness with cutting-edge technologies, Fedegari reduced 50% of steps in the workflow and optimized the manufacturing process with significant time, energy and cost savings.

Fedegari final solution created a cleaner and safer environment, increased Serum’s production capacity and allowed to save costs on maintenance while having fewer machines involved in sterile processing.


Fedegari has worked with Serum exchanging experiences and studying their sterile production process to offer a completely robotized and integrated transfer solution, created ad-hoc for their needs. This way, Serum optimized the transfer of clean closures to the filling line by installing a Fedegari stopper processing system with a tank instead of using a common solution that would have included beta canisters, washers and autoclaves.


We are proud to be serving Serum Institute with our various range of top of the line equipment since two decades and are proud that they are using them to save mankind from one of the worst pandemics ever, said Ajay Mehra from ACE Technologies.

This project consolidates Fedegari’s presence in the Asian market and more specifically in India, where the Group has been present for over 15 years, collaborating with all the main bio-/pharmaceutical companies through the long-term partnership with ACE Technologies. To better support the Indian market, Fedegari has recently opened a Technical Support Center in Hyderabad.

“We will probably supply 40-50 million doses in the next two months”, proudly stated Mr. Adar Poonawalla, CEO of Serum.
Mr. Adar C. Poonawalla

CEO, Serum Institute of India


“We are very proud of our historical collaboration with Serum Institute, the world’s leading manufacturer of vaccines with whom we have been working for more than 15 years. A project like this is a big step towards true integrated engineering and goes far beyond the delivery of stand-alone process equipment. It requires a deep understanding of the end-user real needs to engineer a highly customized solution able to assure the highest reliability and efficiency of the system. Delivering this plant to Serum Institute has been a challenge for both our companies but has allowed to explore new frontiers in the application of robots in critical manufacturing environments. Engineering modern, cost-effective bio-pharmaceutical facilities implies many skills, above all the capability of designing solutions that integrate different machines and processes while assuring higher quality of the end-product.”

Giuseppe Fedegari, President of Fedegari Group

“We believe in international knowledge married together with our major capabilities as manufacturer to achieve the best results: a sterility quality control issue where there is no human intervention is very essential for a product. No human being at any level comes in direct proximity with the vaccines. Our collaboration with state-of-the-art suppliers is crucial to share experiences and technical knowledge that allow our business to remain competitive while saving many lives around the globe”, stated Dr. Cyrus Poonawalla, founder of Serum Institute. (Source:

Dr. Cyrus S. Poonawalla

Founder, Chairman and Managing Director, Serum Institute


Ace Technologies founded in 2000, is best described as a young, effective and on the rise. Since its inception, it has been on a clear path of growth, this can be attributed to its core principles and values of the company which are integrity, understanding, excellence, unity and responsibility. These values have been part of our company’s beliefs and convictions from the early days, and they continue to guide and drive our business decisions.

We continue to acquire and develop core technologies through continuous alliances with renowned partners and suppliers. ACE Technologies also believes in building long-term business relationships through continuous innovation, better service and superior quality.


Serum is ranked as India’s first bio-technology company using cutting edge genetic and cell-based technologies. Serum Institute was founded in 1966 by Dr. Cyrus Poonawalla with the aim of manufacturing life-saving immuno-biologicals, which were in shortage in the country and imported at high prices.

It is estimated that about 65% of children in the world receive at least one vaccine produced by Serum Institute. Its vaccines are recognized by the World Health Organization (WHO) and are used in about 170 countries worldwide in national immunization programs, saving millions of lives worldwide.


Sistema integrato

Fedegari Group is a hi-tech company designing and manufacturing sophisticated systems for producing sterile drugs. Founded in the early 1950s in Pavia by the Fedegari family, who still runs the company today, Fedegari has a global presence in 100 countries with more than 550 employees and a turnover of approx. 75 MEUR, 90% of which is exported worldwide.