Ampoule filling machines

Whenever glass containers are at play, production processes become challenging. Glass ampoules are no exception: cleaning, filling, closing and inspecting the much-used containers require care and precision. At Syntegon, we have a passion for both: our ampoule filling and sealing machines for low to high-output production ensure gentle, hygienic and accurate processing. Different burning stations, filling technologies and handling systems allow us to tailor our systems to your production settings. Our portfolio enables us to easily combine all machines with upstream and downstream equipment such as barrier systems, effectively supporting your entire production line.

Solutions for complete ampoule lines

Opening station for closed ampoules

When it comes to bioprocessing, the systems from Syntegon’s subsidiary Pharmatec flexibly support the production of small and large volume parenterals (SVP/LVP) and infusions (IV). The process solutions comprise modular set-ups of temperature-controlled stainless-steel tanks that can be assembled to meet customer-specific settings. The new, cost-efficient SVP Essential is a fully automated, ready-to-use system to produce simple parenterals such as analgesics, insulin, and generic drugs.

Benefits:

Adaptable to specific room conditions and floor plans
Continuous process monitoring for the highest possible safety
Suitable for toxic substances up to OEB5 in isolators
SVP Essential: less engineering effort, faster delivery times

Our formulation systems

Before and after filling, vials, ampoules, syringes, and cartridges need to undergo a crucial process step. Thorough internal and external cleaning is necessary to remove product residues and other contaminants from the containers’ inner and outer sides. As such, cleaning prevents potentially harmful substances from compromising operator and patient safety. Syntegon’s portfolio of compact pharmaceutical cleaning systems for the low, medium and high output ranges support manufacturers in reaching this goal. The hygienic and ergonomically designed solutions allow to clean a wide variety of containers, with special emphasis on fast and easy operations.

Benefits:

Nearly complete surface cleaning
Application of different cleaning agents
Possible integration into Syntegon barrier systems

Our cleaning machines

Whether you are filling liquid pharmaceuticals into ampoules, vials, injection and infusion bottles, cartridges or syringes: the reliable pre-treatment of containers significantly contributes to product safety. Thanks to a wide range of depyrogenation tunnels and related sterilization technologies, we provide versatile solutions for an effective and sustainable pre-treatment of liquids in open, semi-sealed or closed containers. Dry heat, vacuum, steam/air mixture and hot water shower sterilization help you achieve reproducible treatment quality while optimizing your energy requirements.

Benefits:

Automated filter scans, filter sterilization and container transport for increased efficiency
Highly modular systems allow customized pre-treatment needs
Rapid heating and cooling minimize thermal stress, contributing to overall product safety

Our sterilization & depyrogenation tunnels

Our filling systems for pre-sterilized packaging combine flexibility and precision: a wide range of technologies, including valve piston and peristaltic pump, mass-flow and time-pressure filling, make sure you can fill your products in a highly customized way. Tool-less format changes and filling stations with a variable number of filling heads increase the flexibility of your filling processes. Subsequent sealing is equally versatile, offering you a variety of methods such as gas burning or vacuum stopper insertion for tightly sealed containers. In-process control (IPC) further improves filling quality with constant checks of filling weight and stopper location.

Benefits:

Highly precise filling processes
Combi filling available
Fully integrated barrier system (RABS, closed RABS or isolator)

Our filling systems

Like any pharmaceutical container, ampoules require thorough inspection to ensure patient safety. Our wide range of manual, semi and fully automated inspection machines inspects liquid and lyophilized pharmaceuticals for particles and container defects. Thanks to our long-standing inspection expertise, we offer state-of-the-art technologies for visual inspection and container closure integrity testing (CCIT), including high voltage leak detection (HVLD), static division (SD) and headspace analysis (HSA). Moreover, Syntegon provides fully integrated inline inspection solutions for several inspection tasks such as the detection of container defects.

Benefits:

High output of up to 36,000 units/h (AIM series)
Camera-based and light transmission-based visual inspection
Cutting-edge CCIT including patented Syntegon technology
Modular set-up for fast delivery and rapid customization
Inline inspection: fast reaction in case of particle or glass defects
Inline inspection increases safety and quality during the fill-finish process

Our visual inspection machines

The Syntegon company SBM (Schoeller-Bleckmann Medizintechnik) offers a vast portfolio of versatile sterilization solutions for an effective treatment of porous loads and liquids in open, semi-sealed or closed containers. The vacuum-steam, steam/air mixture and hot water shower processes support you in achieving reproducible equipment and terminal sterilization while optimizing your energy requirements.

Benefits:

Wide process range
Hygienic design
Flexible recipe editor for customized processes
Automatic in-line filter sterilization

Our sterilizers

ARF 1000

Are you looking for a compact, small-batch ampoule filling and sealing machine? Check out the ARF. The intermittent, rotary filling and closing machine reliable fills and seals different types at outputs of up to 6,000 containers per hour – with more than just one set-up. You can either process open and closed ampoules or vials, but also both packaging materials on the same machine. No matter which version you choose, the ARF 1000 stands for reliable, first-class results and offers optional 100 % IPC.

Benefits:

One or 2-head filling station
Digital display to optimally monitor all process parameters
Pharmaceutical safety in all process steps
Fully integrated barrier system (RABS, closed RABS or isolator) available

ALF 4000

Ease of use at high outputs are key characteristic of our ALF 4000 filling and closing machine. As a linear, indexing-motion system, it fills and closes ampoules in the 1 to 30 milliliter volume range. With an output of up to 30,000 containers per hour, the ALF 4000 is not only capable of operating at high production rates. The secure system further supports gentle container handling and precise filling using various filling systems. It is simplified designed makes the ALF 4000 particularly easy to retrofit and provides excellent accessibility for maintenance and cleaning.

Benefits:

Well suited for wall mount and isolator installation
Combination machine (option) can process ampoules and injection bottles, increasing production flexibility
Low number of format parts

ALF 5000

Three different versions for high-output production: this sums up what the ALF 5000 has in store for you. The latest generation of the proven ALF series of filling and closing machines achieves high outputs of up to 36,000 ampoules or vials per hour. You can choose to either process open and closed ampoules or vials, but also both packaging materials on the combi platform. The improved pharmaceutical design and accessibility make the ALF 5000 a benchmark in the high-performance range. Hygienic operations are another mainstay, as the easy-to-clean machine shows a lower contamination tendency.

Benefits:

Easily convertible combi filling system
Gentle processing via carrying rake transport
Integration into barrier systems without difficulty
Different filling systems with 4 to 12 filling points (optional)

Our solutions have got you covered

Automation

Take our data acquisition solutions: they help you to reliably monitor and record crucial process data on both line and container level. SCADA (supervisory control and data acquisition) provides real-time machine and process data in one dashboard, thus enabling transparent line and batch control. SODA (single object data acquisition) fosters supply chain security by managing data for single containers, preventing time and cost-intensive incidents like complaints.

Safety and versatility combined

In-process control, hygienic design and isolator integration ensure that our solutions not only offer maximum versatility, but also highest product safety.

Barrier systems

We focus on each component to make sure it seamlessly interacts with others: safe interfaces between filling machines, isolators and subsequent equipment.