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

• Entire line designed, manufactured, assembled, and commissioned in accordance with latest GMP regulations
• Ensures adherence to stringent quality and regulatory standards

Seamless Automation from Start to Finish

• Servo control system automates processes from tray unpacking and film tearing to conveying, filling, plugging, and tray output
• Electromechanical integrated control for stable, highly automated operations

Versatile Product Range and High-Speed Output

• Handles prefilled syringe sizes from 1ml to 20ml (customizable per specifications)
• Filling range of 0.1ml to 20ml
• High-speed production capacity of 2,000 to 30,000 units per hour

Flexible Configuration Options

• Filling head count from 2 to 10, selectable based on desired output
• Choice of metal, peristaltic, or ceramic filling pumps

Unparalleled Accuracy and Efficiency

• Filling accuracy of ≤ ±1% (dependent on product characteristics)
• Exceptional pass rate ≥99.9%

Safeguarding Product Integrity

• Automated syringe handling via servo system and cylinders
• No friction between plugger and drug solution, minimizing contamination risks
• Stoppers protected by laminar flow, preventing particle exposure

Intelligent Manufacturing Features

• Intelligent testing devices at core stations for automated production control
• Servo-driven components precisely positioned below for clean environment
• Configurable high-performance functions like no bottle-no fill/cap, linked bottle squeeze detection

Aseptic Processing Capabilities

• Configurable CIP/SIP, nitrogen inerting, and vacuum filling systems
• Optional isolator, Open-RABS, and Class 100 purified air systems
• Bag-in/bag-out integration for fully closed aseptic processing

Advanced Automation and Control

• Collaborative robotics for film tearing, de-lining, filling, plugging, weighing
• Automated filling volume calibration
• High-precision colour touch screen HMI, PLC control, and VFD regulation

Tailored Solutions for Your Needs

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

Embrace the pinnacle of prefilled syringe production with our intelligent, automated plastic line - ensuring unmatched efficiency, precision, and regulatory compliance. Contact us today.