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 adherence to new GMP regulations from design to commissioning
• Ensures product quality, integrity, and safety

Seamless Automation from Start to Finish

• Advanced servo control for honeycomb tray unpacking, de-nesting, conveying, filling, plugging, and tray output
• Electromechanical integrated control for stable, high-automation operations

Versatile Production Capabilities

• Accommodates fill volumes from 0.1ml to 20ml
• Output capacities ranging from 2,000 to 30,000 BPH
• Configurable with 2-10 filling heads tailored to your capacity needs

Precise Filling and Dosing Accuracy

• Range of filling pump options: metal, peristaltic, ceramic
• Exceptional filling accuracy of ≤±1% (depending on product characteristics)
• Achieves pass rates ≥99.9% for uncompromised quality

Safeguarding Product Integrity and Sterility

• Automated syringe handling via servo-cylinder systems
• No contact between plugger and drug solution, stoppers protected by laminar flow
• Servo-driven components located below for precise positioning and minimal contamination risk
• Optional CIP/SIP, nitrogen inerting, vacuum filling for viscous products, and more

Advanced Environmental Control and Containment

• Configurable with Open-RABS isolation, Class 100 laminar airflow protection
• Fully closed isolator systems and bag-in/bag-out for enhanced aseptic processing
• Intelligent testing at core stations for comprehensive quality monitoring

Intelligent Manufacturing Capabilities

• No bottle/no fill, no cap, and linked bottle squeeze detection
• Multi-robot collaborative control for automated film tearing, filling, plugging, weighing
• Automated filling volume calibration for precise dosing

Cutting-Edge Process Control and Monitoring

• High-precision color touch screen HMI and PLC automation
• Automatic protection and variable frequency drive control
• Comprehensive production 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 aseptic prefilled syringe manufacturing with our cutting-edge, fully automated plastic PFS line - engineered for unparalleled efficiency, precision, and regulatory compliance. Contact us today to explore this state-of-the-art solution.