Filling of vials in bulk

Pharmaceutical manufacturers have been trusting Syntegon for more than 60 years to process their vials reliably, safely, and efficiently. We have installed more than 1,500 vial filling machines all over the world. They are used to process some of the most valuable and urgently needed pharmaceutical liquids in 24 hour operations, for instance the new Covid-19 vaccines, oncology preparations or other biopharmaceuticals. Either as a classical bulk process with washing and depyrogenation tunnel, or in combination with ready-to-use (RTU) vials in trays – we support you with our comprehensive knowledge and technical solutions.

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Key benefits

Fast

High-speed lines with outputs up to 750/min with a reduced number of size parts support minimal changeover times.

Scalable

From small quantities to large production batches, our systems support you with any production need.

Flexible

A large range of filling volumes and technologies allows you to address changing manufacturing requirements.

The appropriate filling technology for your product

The perialistic pump, for example, is a displacement pump, which presses the product through the filling hoses by means of mechanical hose deformations.

Combine filling technologies according to projects

Our Combi filling station is a highly flexible filling platform, which enables you to use multiple filling technologies and dosing units in a small space. Start with one filling system and retrofit with another or even more, just as your projects require.

Inline inspection solutions

During the filling process, inline inspection systems for empty vials, stopper position or crimp quality further increase product quality and maximize product yield.

Cross-process solutions (KIV)

Our KIV facilitates the tracking and identification of each filled and sealed vial and brings benefits in product safety. Protection against counterfeiting is especially successful when combined with SODA for single object data coding of every single vial within the primary packaging process.

Outstanding machine design

Our machines all feature a clean and hygenic design for easy cleaning operations and the highest operator safety.

Our solutions for vial liquid filling

The FLC 3000 has set trends and delivered proof in many customer applications: its unique combination of flexibility and compact design have made it the preferred choice for safe and efficient filling and closing of vials and infusion bottles in the medium and high output range: 600 vials per minute are possible with a filling range of 0.2 to 500 milliliters. This is achieved with only three format part sets and minimal changeover times. No pharmaceutical filler was built more often as the FLC – with more than 650 installations worldwide.

Benefits:

High process safety and reliability thanks to proven technology
Wide processing area: filling range from 0.2 to 500 ml with only three sets of size parts
Compact GMP-compliant machine design for medium and high output rates

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 vials or ampoules per hour, or both 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. It further features an optional 100 % in-process control (IPC) at constant speeds.

Benefits:

Extraordinary power: outputs of up to 600 vials/min
Clean design meeting newest GMP Annex revisions
Optional 100 % in-process control (IPC)
Modular machine concept tailored to existing production processes and barrier systems

The MLF 300 filling and closing machine for vials and infusion bottles combines medium output with the highest flexibility. Its modular design and large processing range from 2 to 500 milliliters make it ideally suited for versatile applications. You can achieve output rates up to 200 containers per minute. Monoblock versions including crimping in a capsuled design are also available, still featuring a small footprint.

Benefits:

Highly flexible: available as filling and closing machine or as monoblock version with integrated crimping module
Optional 100 % in-process control (IPC)
Enables operation from one side

If you are looking for a flexible filling and closing machine for industrial small-scale production and studies of pharmaceutical liquids in vials, our ARF 1000 is the right choice. The intermittent, rotary machine achieves an output of up to 6,000 containers per hour. You receive the highest flexibility and efficiency combined with a small footprint. The optional 100 % in-process control (IPC) adds to safe and reliable results. We also offer a monobloc version with integrated or separated capping including inline inspection systems. And for everyone looking for even more flexibility: the ARF is also available as a combi machine for vials and ampoules in the smallest space.

Benefits:

Compact and scalable: 1 or 2 packaging types and filling stations
Various options for maximum product yield (e.g. 100 % in-process-control (IPC), repetition of major process steps and integrated inline inspection systems
Tool-free format part changes

The FLT 1000 is your flexible filling and closing machine for clinical trials and small batch production. Its small size, however, doesn’t mean it’s short on features: it combines a large part of the functionality of machines in the medium output range with minimum space requirements. A full-featured filling system ensures automated production and limits product loss. With its output of 30 vials per minute, the FLT fits in every lab or production facility.

Benefits:

Compact size and mobile platform makes the FLT easy to move
Hygienic design for easy cleaning operations
Flexible integration into production lines with Syntegon barrier systems (RABS and isolator)

Highly potent, personalized pharmaceuticals mean small patient populations – and equally small batch sizes. As a highly standardized and modular solution, the Versynta Flexible Filling Platform (FFP) enables manufacturers to approach aseptic filling in a new way.

Benefits:

The ideal solution for small-batch bulk and RTU containers
Flexibility in packaging types and filling systems
Unique transport system for precise and sensitive handling

Just like small batch production, micro batch manufacturing is coming to the fore of everyday pharmaceutical operations. Together with a customer, we are currently testing the second instalment of the Versynta portfolio, the gloveless microBatch working cell.

Benefits:

Suited for all bulk and RTU containers (vials, syringes, cartridges)
Vial closing with classical stoppers, crimp caps, press-on caps
Gloveless operations within fill & finish area

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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

Pack style cracks: vials or bottles come in different shapes and sizes – and with specific challenges. We help you find the matching processing equipment.

Customizable solutions: modularity is a built-in characteristic of our bulk processing solutions. They perfectly blend into your production environment.

Full process expertise: from filling to closing and freeze drying, we have got you covered with a comprehensive portfolio.

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years of experience

patents and patent applications

machines installed world-wide

locations

Vial filling downloads

Vial liquid portfolio

Learn more about our vial liquid portfolio

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Interested in vial filling machines?

Country/Region

Vial filling machine

Filling of vials in bulk

Key benefits

Fast

Scalable

Flexible

Vial filling machines and features

The appropriate filling technology for your product

Combine filling technologies according to projects

Inline inspection solutions

Cross-process solutions (KIV)

Outstanding machine design

Our solutions for vial liquid filling

Interested?

Service Agreements

Digital Solutions

Parts

Maintenance

Technical Support

Modernizations

Training

Expert Services

Why choose a Syntegon vial filling machine?

About us

Vial filling downloads

Read our latest pharma news

Interested in vial filling machines?

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