Vaccine manufacturing equipment for every step

Vaccines are one of the most successful public health interventions in history. They have dramatically reduced the incidence of many infectious diseases worldwide. For manufacturers looking to contribute to public health through innovative vaccine solutions, Syntegon provides cutting-edge equipment for every stage of vaccine production.

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Solving your vaccine manufacturing challenges

A fast-growing market

Analysts predict the vaccine market to reach more than USD 88 billion by 2029. We will be happy to support you in gaining your share with seamless vaccine manufacturing line concepts from a single source.

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Pharmaceutical RTU filling line handling a tray of vials, demonstrating adaptability to various output requirements

Meeting output needs

Vaccine lines typically require speeds from 400 to 1,000 containers per minute. Whatever your vaccine production output goals, Syntegon has the right filling solution tailored to your needs.

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Regulatory compliance

Navigating stringent regulations and ensuring continuous compliance is quite a challenge. Trust in our experts with long-standing market knowledge. They will be happy to support you in meeting all requirements.

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Pack styles and dosage forms

Vaccines can be administered in several different dosage forms and are delivered in different primary packaging containers. While most vaccines are still provided as liquids in syringes or vials, other dosage forms are also gaining ground with new drug products. No matter which dosage form you are producing, and which container type you need for your vaccine production – our seamless solution portfolio has got you covered.

Syringes are the go-to packaging for many vaccines. The containers ensure precise dosing and make handling easier, reducing waste and minimizing costs for high-value drugs. Whether you need a solution for bulk or ready-to-use, small batch or high-speed filling, our broad portfolio will certainly have the matching solution for your safe and gentle syringe processing.

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Vaccine vials are available in liquid and lyophilized form, offering exactly the flexibility you need to match your storage and stability requirements. Syntegon has more than 60 years of experience and more than 1,500 vial filling and closing machines installed at customer production sites worldwide. We offer solutions for plastic or glass bulk and ready-to-use vials in sizes from 2 to 500 milliliters. You name it, we have it!

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Whether for small batch production or high-speed lines, Syntegon provides end-to-end solutions for RTU vaccines – ensuring aseptic processing, cost efficiency, and minimal product loss. Long-standing expertise and seamless integration from a single trusted source make sure you receive fully aseptic, cost-effective handling and filling equipment with consistent accuracy and minimal product loss at all speeds.

Discover our RTU portfolio

Oral dosage vaccines simplify administration and make vaccine production more efficient, helping you scale manufacturing while reducing complexity and costs. Are you producing or developing a vaccine that is administered via tablet or capsule? Syntegon has you covered with a wide range of manufacturing equipment for OSD forms.

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Healthcare professional administering a vaccine to a child, showcasing the role of Syntegon's RTU systems in ensuring safe and sterile biologics processing

Vaccine production

We understand the complexities involved in vaccine manufacturing. Our state-of-the-art equipment and innovative technologies are tailored to enhance every stage of the process, ensuring that vaccines are produced efficiently, safely, and in compliance with stringent regulatory standards. Whether you are developing new vaccines or scaling up production of existing ones – we offer you seamless solutions along the entire vaccine manufacturing process.

Vial vaccine line with isolator and lyophilization

Freeze-drying is the key to ensuring a longer shelf life for some vaccines. Our line configuration example navigates you through all the steps you need for your lyophilized vaccines manufacturing. With our seamless portfolio, we will make sure you bring your vaccines to the patients safely.

Simply scroll over the respective steps and explore our solutions. Our experts will be happy to talk you through the process personally.

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Vaccine production begins with cultivating the selected organism under controlled conditions to optimize yields. Once the biomass reaches the desired state, it is harvested via centrifugation or filtration. Our solutions ensure precise control, efficient separation, and regulatory compliance.

Explore our state-of-the-art fermentation and harvesting solutions.

Purification removes unwanted contaminants while preserving vaccine efficacy. This includes viral inactivation through thermal or chemical treatments and multi-stage filtration. Our technologies support a streamlined, compliant purification process for consistent product quality.

Find out more about our purification solutions.

During formulation, the purified vaccine is combined with stabilizers, adjuvants, or other excipients to ensure efficacy, stability, and safe administration. The advanced Pharmatec systems support precise dosing, homogenous mixing, and scalable production.

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The formulated vaccine is filled into vials under sterile conditions to avoid contamination. Our flexible filling and closing platforms further make sure that your vaccine products are closed safely and reliably until administration – in the low, medium, and high output range.

Take a look at our vast portfolio of filling and closing platforms.

Vaccines require reliable sterilization to ensure maximum pharmaceutical safety. The Syntegon subsidiary Schoeller-Bleckmann Medizintechnik (SBM) offers solutions that balance standardization with customization, ensuring sterilization that is tailored exactly to your process requirements.

Find the ideal sterilization solution for your vaccines.

Lyophilization is the key to ensuring a longer shelf life of your vaccines. Our freeze-dryers save space in the aseptic filling environment without sacrificing performance. Moreover, our state-of-the-art loading and unloading system achieves the highest speed in the market.

Explore our new Telstar freeze drying portfolio.

Inspection is mandatory for parenteral pharmaceutical products and contributes significantly to patient safety. We offer you state-of-the-art technologies for visual inspection and container closure integrity testing (CCIT) for manual, semi- and fully automated operations.

Find the right platform for your vaccine inspection.

Ready-to-use syringe line configuration example

RTU syringes save time and costs, as they can be processed in large quantities without upstream cleaning, siliconization, and sterilization. Our RTU syringe lines offer high-speed, flexible filling with fast changeovers that support both high-volume vaccines production and smaller, specialized batches.

Simply scroll over the respective steps and explore our solutions. Our experts will be happy to talk you through the process personally.

Connect with our experts Explore our RTU syringe solutions

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Explore our advanced formulation solutions.

Tubs with syringe nests are packed in either single or double bags. They are loaded into automatic bag and tub opening equipment, where the bags and the tubs’ Tyvek film and top layer are removed fully automatically. Our ABO and ATO equipment ensure reliable transfer and opening of your bags and tubs.

Check out our ABO/ATO bag and tub opening equipment.

Once the nests are removed from the tubs, the syringes are filled and sealed inside the nest. Our filling and closing platforms make sure that your products are filled with the highest possible accuracy and the syringes are stoppered with maximum precision.

Take a look at our vast portfolio of filling and closing platforms.

Vaccines require reliable sterilization to ensure maximum pharmaceutical safety. In the case of nested syringes, the tubs are sterilized at 121 degrees Celsius. Our sterilization methods for nested syringes are gentle on both the packaging and the medicines.

Find the ideal sterilization solution for your vaccines.

Fully automated systems cover visual inspection and leak detection on a single platform, checking containers for cosmetic defects, intrinsic and extrinsic contamination, and leaks. Our solutions with built-in de-nesting and re-nesting features handle the syringes gently during the process.

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IDT Biologika – the world’s fastest filling line with 100 percent check weighing

Contract manufacturers require equipment that is ready to produce large batches safely and reliably in the shortest possible time. This is exactly what a line from Syntegon is doing at IDT Biologika: it processes 80 to 100 million 2R vials per year with 100 percent in-process control.

Bavarian Nordic – new isolator filling line for BSL2 vaccines

Vaccines for human viral diseases are among the most successful inventions in medical history. However, they also lead to some challenges – which Bavarian Nordic is tackling with its new isolator filling line for freeze-dried and liquid vaccine serums from Syntegon.

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Aspen Pharmacare – Alice to the rescue

Alice is several feet long and the silent hero at Aspen’s production facility in Gqeberha, South Africa. Alice is based on the successful ALF platform from Syntegon and fills vaccines into vials – and did so in 24/7 operations for Johnson & Johnson Covid-19 vaccines during the pandemic.

Janssen Vaccines – expanding API production

Adding vaccines and monoclonal antibodies for cancer treatment to its portfolio, Janssen required increasingly flexible manufacturing processes. Our subsidiary Pharmatec installed a highly customized system that enables switching between different formulation volumes easily.

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AJ Vaccines – ready for Annex 1

According to the revised EU GMP Annex 1, sterile production must take place under RABS or isolator conditions to ensure maximum product and operator protection. AJ Vaccines decided to act early and upgraded its filling and closing machine with a complete RABS from Syntegon.