Syringe filling machines

Syringes are the go-to packaging for a variety of highly potent parenteral drugs, including innovative biopharmaceuticals. The containers increase dosing accuracy, making it easier to handle the costly drugs. Efficiency as well as product and operator protection are key during the entire filling process, from de-nesting to filling and closing. We offer you a large variety of fully automated syringe filling lines that cater to maximum product safety and process flexibility. From single pack styles and filling technologies to a full combi line, from small batches to high outputs – you name it, Syntegon has it!

Want to take a deep dive into syringe filling?

Join our Senior Product Manager Klaus Ullherr, a true pre-filled syringe expert, and explore the entire process – from bag opening and sterile packaging transfer to filling and stoppering methods. It’s worth every minute!

Want to take a deep dive into syringe filling?

Solutions for complete syringe lines

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.

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

Whether you run a small, medium, or high output line, safe processes are paramount to maintaining product quality. With highly automated bag and tub opening solutions for ready-to-use containers, we help you process pre-filled syringes both safely and efficiently. Especially in nested syringe application settings, our ABO automatic bag openers and ATO automatic tub openers minimize operator contact and contamination risks through fully automatic, aseptic removal processes.

Benefits:

Safe and reproducible separation of bags and tubs
Clear separation of clean room areas
Reliable and reproducible bag handling

Our RTU upstream processing solutions

Processing pre-filled syringes with expensive parenteral drugs requires utmost care and precision. Syntegon’s comprehensive filling and closing systems meet this requirement, and many more: flexible handling allows for a gentle removal from the nest, while in-process control (IPC) further improves filling quality through essential filling weight and stopper location measurements. The wide variety of filling systems, including peristaltic pumps, add to the overall process hygiene. Vent tube or vacuum stopper insertion makes sure the syringes are tightly sealed.

Benefits:

Hygienic filling and closing of nested, pre-sterilized syringes
Aseptic transfer possible with RABS or isolator
Fully automated processes with minimal operator intervention
Safe and gentle product handling

Our filling systems

Our pre-filled syringe lines make sure syringes are handled with care right from the start. Dedicated handling units allow syringes to be precisely removed from nests and tubs without operator intervention. As a result, individual syringes can be fed into integrated inspection stations more easily and contaminant-free. As experts in nested syringe operations, we have developed exclusive solutions for the highly automated de-nesting and secure positioning of pre-filled syringes before downstream processing. The devices can be effectively combined with re-nesting and inspection platforms.

Benefits:

Gripper/pusher technology for careful syringe removal and placing on conveyor
Secure and controlled syringe position during entire de-nesting process
Automated nest and tub stacking
Camera-based identification of tub description

Our de-nesting solutions

The syringe process does not stop after filling. Instead, it needs further sophisticated steps: from rod insertion to applying visible, easily identifiable labels to the outside. We combine these two steps in a single platform: with the Rod Inserter and Labeler (RIL), plunger rod insertion and label application are realized at high speeds for both glass and plastic (COC) syringes, ensuring sterile downstream handling at its best.

Benefits:

High-speed handling of up to 400 syringes per minute
Accurate rod placement for maximum sterility
Vision-controlled plunger rod mounting for added precision
Compact and clean design

Our labeling machines

syringe-processing-rod-inseration-and-labeling

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 defects detection 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

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

RTU syringe 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 of RTU syringe filling machines comprises systems that effectively support small, medium and high output production of liquid and lyophilized pharmaceuticals.

Learn more

Bulk syringe filling

Bulk processing is a challenge of its own: the containers must be processed at high speeds, asking for reliable and fast operations. Syntegon’s bulk syringe machine offers you precision and ease of use: accurate feeding of the syringe barrel and a variable number of filling and closing stations allow gentle processing of different sizes of bulk syringes.

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.

Safety & Versatility

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.