Medical device assembly, labeling, handling & packaging

Medical devices such as auto-injectors, safety devices and pens contribute to beneficial patient outcomes, as they support easy administration and therapy adherence. Before the medication reaches the patients, the devices must be reliably assembled, labeled and packed. This is where the Syntegon solutions come into play: our systems cover the safe assembly, labeling, handling, and secondary packaging of medical devices. Thanks to their modular platform design, our manual, semi and fully automated systems allow for a high level of customization, helping you meet market requirements, while always having patient safety in mind.

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Key benefits

Scalable

Our flexible standard platforms can be easily adapted to work at increased capacity, securing your present and future production goals.

Flexible

Medical devices come in many shapes and sizes, which our machines assemble, label and pack reliably – now and in the future, according to market and customer´s requirements.

Agile

Our systems enable speedy and secure changeovers, allowing you to easily switch between batches and device types.

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Assembly & Labeling solutions for MedTech devices

Have a look at our portfolio of reliable assembly and labeling solutions for different MedTech devices. Agile and quick format changeovers and precise labeling are just a glimpse of the possibilities.

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Range manual assembly - RMA

This RMA machine is designed for small batches and clinical trials with auto-injectors, pens and other medical devices. It features a workstation for manual loading and unloading of components and devices; all other processes are performed automatically. This way, the range manual assembly machines achieve an output of between one and three devices per minute.

Our range auto-injector assembly and labeling machines achieve outputs of up to 200 parts per minute and can be flexibly automated according to your specific production requirements. We offer a comprehensive portfolio of rotary or linear platforms that supports rapid format changeovers for increased production flexibility.

Benefits:

Highly adaptable machine concept will support high level of utilization
Clear process overview and good machine accessibility
Automatic device transport between different modules
Efficient footprint through compact design
Hygienic design for easy cleanability
Modular design for future upgrades in speed, products or automation
Fully integrated controls and HMI
Machine output of up to 200 parts per minute

Syntegon Range Device Assembly (RDA) machine for auto-injectors

Contractors and service providers of auto-injectors need the highest flexibility to meet growing market demands. Check out our Range Device Assembly (RDA) machines: they can assemble and label all known auto-injector types, including yours!

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The range pen assembly systems and matching labeling machines from Syntegon are designed for outputs of up to 300 parts per minute. Just like our auto-injector assembly systems, they can be flexibly automated according to your specific production requirements. We offer a comprehensive portfolio of rotary or linear platforms that support low to high output production, as well as rapid format changeovers for increased production flexibility.

Benefits:

Assembly of new devices can be implemented easily and at low costs
Quick changeover between the different parts
Automatic device transport between different modules
Small footprint platform with high level of modularity
Hygienic design for easy cleanability
Modular design for future upgrades in speed, products or automation
Fully integrated controls and HMI

The Syntegon tray loader is a high-speed system for fast and reliable loading and unloading of primary containers. This compact and GMP-compliant machine adds to our extensive portfolio of handling equipment and can either be integrated into a new line or retrofitted to an existing installation. The conveyor transport system allows 100 % traceability of containers from the upstream machines to the tray loading station. Rejects from the upstream machines can thus be discharged on the tray loader. Additionally, automatic systems for in-line inspection and marking such as vision control and lasers can be integrated. A separate station for in-process control (IPC) sampling of containers for offline checking is available as an option.

Benefits:

High output up to 600 products per minute
Large buffer capacity with up to 4 trays and separate reject stations
Ergonomic and convenient tray handling with tiltable plates and optional vertical adjustment
Reject station and separate IPC station for offline checks outside the tray loader
Gentle and safe handling of cartridges by scroll transport and vacuum star wheels
In-line vision inspection of containers via cameras possible
Integrated coding station as an option (e.g. laser coding of plungers or caps)

Syntegon offers customized solutions for the direct labeling of medical devices such as pens, auto-injectors, catheters, inhalers or other MedTech products in primary and secondary packaging. Depending on your specific requirements, we will design the suitable labeling solution in terms of output, label orientation and dispensing accuracy, as well as special functions like online printing, code verification, or false label rejection. A variety of different handling and transport systems are available depending on the shape and characteristics of the devices or packages, and your output requirements.

Benefits:

Excellent overview of all stations and processes
Good accessibility to the entire machine for easy format setting
Tailor-made concepts based on your individual requirements
Large variety of handling solutions for different automation and output levels
Line integration of further Syntegon machines or from external partners
One stop shop for filling, closing, assembly, inspection, labeling and packaging

Syntegon offers customized case packing solutions for the secondary packaging of medical devices such as pens, pen needles, auto-injectors, catheters, inhalers, infusion sets, or cannulas. Depending on your specific requirements, we will design the suitable concept in terms of loading pattern, requested output and case dimensions. We offer different handling systems for the feeding and arranging of medical devices in their packages, from simple stacking units to multi-axis industrial robots. If you are looking for standardized machine platforms in the up- or downstream packaging process, we can integrate modules from Syntegon or external partners into a line solution.

Benefits:

Excellent overview of all stations and processes
Good accessibility to the entire machine for easy format setting
Tailor-made concepts based on your individual requirements
Large variety of handling solutions for different automation and output levels
Line integration of further Syntegon machines or from external partners
One stop shop for filling, closing, assembly, inspection, labeling and packaging

Use case scenarios

Integrated line assembly and packaging

Our integrated pharma solutions offer you services that go far beyond our broad portfolio of machines and process equipment.

Special devices on request

Cannulas, inhalers, catheters, line sets, infusion sets and needle assembly are only some of the devices and requirements our systems can handle.

PCI Pharma Services relies on RDA assembly machines from Syntegon Technology

Diabetes and obesity drugs

Explore Assembly and Labeling solutions for medical devices

Quick format change

Format changeovers can be done quickly and easily with standard tooling and by trained operators.

High speed device and packaging marking

We offer inline laser or other marking technologies for different containers and packaging styles.

Technical data of our assembly machines

Footprint from

square meters

More than

years of experience

Up to

devices per minute

Technical data - Device assembly

Machine dimensios:	Rotary platform approx. 4x5m Linear platform from 4x8m
Site range:	For all available devices
Output:	0-200 auto injections/min.
Capacity:	Manual: 2 mio.+ devices/ year (3 shifts, 8 h, 360 days/year) Semi-automatic: 10 mio.+ devices/ year (3 shifts, 8 h, 360 days/year) Fully- automatic: up to 50 mio. devices/ year (3 shifts, 8 h, 360 days/year)

Syntegon standard assembly machines are designed for a long lifetime, and 24-hour operations. All components are from recognized brands, and obtainable all over the world. We never use any component or automation part to 100%, always leaving a buffer capacity. We have a large range and pre-standardized configurations to cover most needs. Using our standardized modules, we secure a fast and reliable execution.

Interested?

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Assembly

This machine is designed for small batches and clinical trials with auto-injectors, safety devices, pens, and other standard devices. It features a workstation for manual loading and unloading of components and devices; all other processes are performed automatically. This way, the range manual assembly machines achieve an output of between one and five devices per minute.

range-manual-assembly-machine-01

The semi-automatic machine comes with a manual infeed, while all assembly processes are automated. An upgrade to an automatic infeed is possible at any time. With an output of up to 50 devices per minute, the machines of this range have a big selection of add-on modules.

auto-injector-device

Our fully automated device assembly machines can assemble up to 200 devices per minute. The fully automatic infeed and outfeed is fully integratable with upstream and downstream equipment. Moreover, we offer you a large selection of add-on modules like labelling, tracing etc.

machine-for-pen-assembly-fully-automatic

Our labeling solutions span from manual loads to 500 automatic labels per minute. All labeling systems are fully servo-driven and have an integrated HMI with full control of all parameters. To maintain high outputs, the platform features label reject before application, and automatic reel exchange. Moreover, you receive integrated vision verification and a selection of printing technologies.

high-speed-labelling-machine

Packaging

Our case packers are highly modular and can fit any product need. The high-speed unit features with several additional options, e.g. for traceability. It is adjustable for different sizes of cartons and shipper boxes. Thanks to its modularity, our case packers can accommodate several different layout scenarios.

Handling

The TLU is a highly versatile tray handling unit, which can be adjusted and designed to accommodate most containers at speeds up to 600 units per minute. We can adopt UDI to individual containers at maximum speed with different marking technologies.

The Syntegon rondo tray loader and unloader is your ideal solution with speeds up to 600 containers per minute. The systems can be integrated upstream or downstream, with additional modules for marking and integrity checking.

pharma-injection-02

Our de-nesters and re-nesters are adaptable for almost any upstream or downstream equipment like inspection machines. They can run with or without glass-to-glass contact and are suited for both nested and bulk containers.

nester

Service Agreements

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Digital Solutions

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Parts

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Maintenance

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Technical Support

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Modernizations

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Training

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Expert Services

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About us

Our Range 2.0 moves the boarders of flexibility and scalability into the future. We are ready to implement the ideal and secure solution to cater for our customers’ needs – whether known or unknown at this point in time.

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years of experience

patents and patent applications

machines installed world-wide

locations

Our expertise, your advantage

PCI Pharma Services relies on RDA assembly machines from Syntegon Technology

A success does not come by chance! PCI Pharma Services relies on the auto-injector device assembly machine from Syntegon. Our solutions are designed to meet market requirements and standard device manufacturers’ specifications, while always having patients’ safety in mind.

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We are highly trusted

Whatever business case you are facing, we are the partner you can rely on. We also have a solution for your products.
Our services include feasibility studies, conceptual, basic, and detailed designs, as well as construction management and validation services for the GMP area.
As a leading provider of processing and packaging technology, we provide all necessary equipment for handling, assembly, labeling and packaging in a comprehensive portfolio.
Are you looking for advice on our assembly, labeling and packaging solutions or do you have a specific project in mind? Get in touch with our experts!

Medical device assembly downloads

Product portfolio for Range device assembly machines

Have a look at the entire portfolio for a comprehensive overview

Handling

Various solutions for handling up to 600 parts per minutes, with or without glass contact

Flexibility for Patients and Drug Manufacturers

Flexible assembly and secondary packaging

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Frequently asked questions

Yes, our machines are designed to span a wide device range and don’t impose any dimension limits.

Yes, we cover systems design and processes in-house and offer engineering to order, thus having full control of all size-related aspects.

Yes, our machines are designed to be adapted regarding capacity as well as devices.

Yes, our machines are designed especially for the support of multiple device brands and types within the same machine. The range concept also makes it possible to implement future formats without reorganizing the machine, layout or program.

Interested in medical device assembly and labeling solutions?

Country/Region

Medical device assembly

Key benefits

Scalable

Flexible

Agile

Medical device assembly solutions & features

Assembly & Labeling solutions for MedTech devices

Range manual assembly - RMA

Use case scenarios

Integrated line assembly and packaging

Special devices on request

PCI Pharma Services relies on RDA assembly machines from Syntegon Technology

Diabetes and obesity drugs

Explore Assembly and Labeling solutions for medical devices

Quick format change

High speed device and packaging marking

Technical data of our assembly machines

Interested?

Different types of machines

Assembly

Pilot assembly

Semi-automatic assembly

Fully-automatic assembly

Labeling machines

Packaging

Case packers

Handling

Tray loading unit (TLU)

Rondo tray handling (USM)

De- and Re-nester (USD/USR)

Why choose a Syntegon MedTech Assembly machine?​

About us

Our expertise, your advantage

We are highly trusted

Medical device assembly downloads

Product portfolio for Range device assembly machines

Handling

Flexibility for Patients and Drug Manufacturers

Read our latest pharma news

Frequently asked questions

Is the design of your devices compatible with the Syntegon systems?

Does our machine meet your space requirements?

Can your machine be expanded later?

Do your machines support multiple devices?

Interested in medical device assembly and labeling solutions?

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Why choose a Syntegon MedTech Assembly machine?