Aseptic pre-filling and sealing syringe lines are mainly used for the unpacking, tearing, filling and pluging of disposable syringes in honeycomb trays in pharmaceutical plants. It's mainly for the production and packaging of various aseptic products such as vaccines, monoclonal antibodies, small molecule heparin, insulin and hyaluronic acid.

Performance Features

Stringent Compliance and Quality Assurance

• Designed, manufactured, and commissioned in full adherence to the latest GMP regulations
• Ensures uncompromising product quality, integrity, and safety

Seamless Automation from Start to Finish

• Automated processes from tray unpacking and film tearing to filling, plugging, and tray output
• Electromechanical integration with servo control for stable, high-automation operations

Versatile Filling Capabilities

• Accommodates filling volumes from 0.1ml to 20ml
• Output capacities ranging from 2,000 to 30,000 units per hour
• Filling head configurations from 2 to 10 units based on capacity needs

Precision Filling with Advanced Pump Options

• Various filling pump selections including metal, peristaltic, and ceramic pumps
• Filling accuracy of ≤ ±1%, depending on product characteristics
• Exceptional pass rates of ≥99.9%

Uncompromising Product Protection

• Automated syringe handling with servo system and cylinders
• No friction between plugger and drug solution, avoiding contamination
• Stoppers protected by laminar flow to minimize particle exposure

Intelligent Manufacturing Features

• Intelligent testing at core stations for comprehensive process control
• Servo-driven components below frame for precise positioning and minimal contamination
• Configurable CIP/SIP, nitrogen inerting, and vacuum filling systems
• Optional isolator, Open-RABS, and Class 100 laminar flow systems for aseptic protection

Advanced Automation and Control

• No bottle-no fill/cap and linked bottle squeeze detection
• Collaborative robotics for film tearing, filling, plugging, and weighing
• Automated filling volume calibration
• Bag-in/bag-out systems for fully closed aseptic processing

State-of-the-Art Process Monitoring and Control

• High-precision colour touch screen HMI and PLC automation
• Automatic protection and variable frequency drive control
• Comprehensive production process monitoring and data acquisition

Tailored Solutions for Your Unique Needs

• Customizable configurations to meet your specific requirements
• Scalable and future-proof for evolving manufacturing demands

Elevate your prefilled plastic syringe production with our intelligent, automated line - delivering unmatched efficiency, precision, and regulatory compliance. Contact us today to explore this cutting-edge solution.