Cartridge filling machines

Performance meets precision in Syntegon’s cartridge filling and capping portfolio. Our solutions for all output ranges help you process cartridges at optimum conditions. From accurate positioning under the working stations to low-particle capping with patented technologies, our cartridge filling systems reliably support each step of your production cycle. High-quality operations are equalled by a modular and space-saving design, facilitating the integration into state-of-the-art production lines.

We are Syntegon.
We are cartridge.

Cartridge processing is not just a production step – it’s a complex task that calls for support from a leading equipment manufacturer. If you are curious to find out why we are the undisputed number one in this field, explore our videos!

cartridge-processing-solutions-for-complete-cartridge-lines

Solutions for complete cartridge lines with an output of up to 400 pcs./min.

cartridge-processing-solutions-for-complete-cartridge-lines-01

Solutions for complete cartridge lines with an output of up to 600 pcs./min.

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

cartridge-processing-formulation-systems

Sterility matters across the entire aseptic process – before, during and after sterile filling. Especially highly potent and/or freeze-dried products pose a risk to operators and patients after filling, as product residues or contaminants on the containers’ outer wall might affect the health of personnel. Syntegon‘s external washing solutions keep the outside surfaces of filled and sealed containers clean: high-pressure nozzles wash off any excess product, while keeping the closures intact.

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 and bulk containers 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

cartridge-processing-filling-and-closing

Aseptic filling is all about product safety – and thus the separation of operators and pharmaceutical ingredients. Isolator technology helps to build this crucial barrier. With over 40 years of US-based and 25 years of German-based experience in the design and manufacture of barrier systems, Syntegon has established a comprehensive portfolio, including open RABS, closed RABS, containment and isolator systems. We focus on each component to make sure it seamlessly interacts with others: safe interfaces between filling machines, isolators and subsequent systems, e.g., freeze-dryers or capping machines are a top priority.

Benefits:

Safe filling of aseptic and highly potent products
Intensive research for RABS, isolator and related barrier technologies
Isolator, bio-decontamination and air-handling from a single source

Our barrier systems

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

Like any pharmaceutical container, pre-filled syringes 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 empty vial, crimping and stopper seat inspection.

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 detection
Inline inspection: increases safety and quality during the fill-finish process

Our inspection machines

Pens and cartridges are a winning team, provided they are assembled in an efficient, fully compliant way. Our modular assembly systems with scalable levels of automation make sure this is the case: they reliably support the production of standard 4-piece disposable pens and come in different designs according to your desired production rates. The rotary table version covers lower and medium outputs, while a linear transport system takes care of high-volume batches.

Benefits:

Good accessibility for easy format setting
Flexible modular design for future retrofits
Real-time machine monitoring via HMI

Our pen assembly & labeling machines

Bulk cartridge filling

Bulk processing is a challenge of its own: the containers must be processed at high speeds, asking for reliable and fast operations. Our broad range of flexible cartridge filling machines makes sure you achieve the desired throughput at peak efficiency. Impressive processing ranges, simple changeover concepts and fully automated systems make sure you can reach this goal in a GMP-compliant way.

Learn more

RTU cartridge filling

With decades of experience, we offer you a broad range of flexible syringe, cartridge and vial platforms, covering upstream and downstream processes. Our portfolio comprises systems that effectively support small, medium and high output production of liquid and lyophilized pharmaceuticals.

Learn more

Versynta – Our small batch portfolio

Versynta is our name for flexible small and micro batch filling operations. The Flexible Filling Platform (FFP) is ideally suited for small batches up to 3,600 containers per hour for vials, syringes, and cartridges, both bulk and RTU. The gloveless and fully robotized Versynta microBatch working cell processes aseptic and high-potent micro batches within a fully integrated machine and isolator unit.

Learn more

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

Glove testing

Thin elastomer gloves often constitute the sole barrier between isolated machines and operators. As such, they prove critical to many different barrier systems, and hence require regular and reproducible testing.

Tray loading

Gentle, safe, and fast – these are the top priorities when tray loading cartridges or vials. Syntegon’s loading solutions are designed for smooth transport and high output, processing up to 24,000 units per hour with reduced error rates.

Our expertise, your advantage

Customers from around the globe rely on our cartridge filling and closing expertise. We have supported some of the most renowned industry players in boosting their efficiency, expanding operations or upgrading their equipment to meet latest manufacturing standards. Explore our customer cases to find out more about the many areas of application.