Syntegon enhances inspection portfolio with RTU handling equipment

The market for ready-to-use (RTU) syringes is growing rapidly. In fact, experts anticipate an annual growth rate of about eight percent over the next ten years. In response to this demand, Syntegon has expanded its inspection portfolio with the new AIM DIRect to include integrated de-nesting and re-nesting technologies for nested syringes into its inspection lines.

A rising demand for RTU syringes

RTU syringes are sterilized, pre-filled with an exact dosage of medication, and sealed for immediate use. Their market growth is fueled by several key factors. They eliminate the need for preparation, saving valuable time for healthcare providers, especially in emergency situations. They also offer enhanced convenience, particularly for patients requiring frequent injections, such as those with chronic conditions. With pre-measured doses, RTU syringes ensure precise administration, minimizing the risk of dosing errors. The rising demand for injectables is further driven by advancements in oncology, diabetes treatments, RNA-based vaccines, and cell and gene therapies, with over 99% of these therapies being delivered via injection.

Benefits and challenges of RTU syringe nests

RTU syringes in a nest offer secure handling and optimal protection. Syringe nests help organize syringes efficiently, ensuring they are stored compactly and safely. They provide crucial protection during both storage and transportation by keeping syringes in a stable, upright position, which minimizes the risk of breakage.

Since inspection is a crucial step in ensuring the quality of pharmaceuticals, manufacturers using RTU syringes in their production need reliable solutions for the automated handling of syringes and their nests, such as de-nesters and re-nesters. However, there are challenges associated with syringe nests during the inspection process. Improper handling can lead to air bubbles, which may increase the risk of false rejects. Additionally, only fully filled syringe nests should be delivered after inspection, ensuring each nest contains the correct number of syringes.

Automated de-nester and re-nester AIM DIRect

The new Syntegon de-nester and re-nester AIM DIRect is designed to efficiently and safely separate syringes from nests for inspection and subsequently return the accepted syringes back into the nests. Seamlessly integrating with our AIM 2 and AIM 5 syringe inspection lines, this module ensures gentle handling of syringes while maintaining high throughput of up to 400 containers per minute.

Your key benefits at a glance:

Non-glass-to-glass contact: minimizes cosmetic defects by ensuring syringes are picked up without direct contact, ideal for both glass and plastic syringes
Reduced false rejects: prevents errors like air bubbles or cracks, improves inspection accuracy, and reduces false reject rates
Only full nests: empty spaces caused by rejected syringes are automatically filled, ensuring only complete nests exit the re-nester
Increased safety: protects syringes during de-nesting and re-nesting, reducing the risk of contamination or damage
Quick format changeover: enables efficient adjustments to different syringe types and sizes
Customization options: additional features like an overhead conveyor to optimize floor space or extra buffer towers to store more nests

See our new AIM DIRect in action

Interested in a live demonstration of our de-nester and re-nester solution? Visit our shop floor to experience it firsthand and discover how our other inspection technologies can help you meet the latest safety standards. The whole team is looking forward to welcoming you here are our Center of Competence for Inspection in Japan.

Get in touch with our global product manager Leoni Ransmann today to arrange a visit!