Pre-filled syringe filling and sealing line. Nest Prefill Syringes Filling and Plundering Machine

This aseptic pre-filled syringe filling and sealing line is available for all kinds of bagged/nested box plastic/glass pre-filled needles. The pre-filled syringe filling line adopts a stable and speed adjustable conveyor system. Keeping class A sterilized condition after entering filling system. Servo drive control, smooth transportation. High accuracy filling from water-like up to high viscosity with servo control.

The design, materials, manufacturing, assembly and commissioning of the whole pre-filled syringe filling line, pre-filled syringe filling machine , PSF syringe filling machine ,PFS filling machine ,Nested Prefilled Syringe & Stoppering Machine ,Combo Filling & Stoppering System ,Semi-Automatic Pre-Fillable Syringes & Nested Stoppers ,Plunger Rod Insertion, Finger Grip Placement & Labeling System , Individual Pre-Fill Syringe Filling & Stoppering System ,Cartridge Filling, Sealing & Stoppering System manufacturing process are in accordance with the new GMP regulations.

Drugs Packaged in PFS are:

Vaccines, Blood Stimulants, Therapeutic Proteins, Erythro Proteins, Interferons, Rheumatoid Arthritis, Eye Surgeries, Diabetes, Migraine, Anaphylactic Shock, IMW-Heparin, Infertility, Psoriasis, Allergies, Osteoporosis, Opthalmic Requirements, Skin Treatments, Spondylitis, Ankylosing Arthritis, Sclerosis, Venous Thrombo Embolism (VTE), Anti-Thrombotics, Biotech Drugs, Specialized Therapies.

Aseptic syringe filling Line

Anyone administering a traditional injection from a vial might typically have to read the required dose from the physician’s dosing directions, withdraw from the vial slightly more formulation than is required, invert the syringe to allow any air bubbles to reach the top, depress the plunger slightly to expel any air, and finally, depress the plunger still slightly further to leave precisely the required dose, which they measure using the scale along the syringe barrel. PFS simplify eliminates all these processes & operations.

These PFS filling machines adopt servo control system to automatically complete the processes of honeycomb tray unpacking, tearing film, conveying, filling, plug feeding, plug filling and tray output. It’s with electromechanical integration control, stable operation and high degree of automation.

Applications: 1ml – 20ml (according to user specifications)

Filling range: 0.1ml-20ml

Capacity: 2000-10000 per/hour

Filling head: 2-10 pcs, choose according to capacity.

Various types of syringe filling pump options:  metal pump, peristaltic pump, ceramic pump

PFS machine filling accuracy: ≤ ± 1% (depending on the characteristics of the medicine
Pass rate ≥99.9%;
Automatic removal and return of the syringe from the honeycomb tray by mean of a servo system combined with a cylinder.

The machines we present are advance motion controller-based PFS filling and plungering machines with servo drives. The filling operation can be propelled by high precision rotary piston pumps or peristaltic pumps, depending upon the nature of product and client’s requirement.

It has dedicated plungers loading station with linear & rotary vibrator bowl and plunger bags keeping station. Dosing station is equipped with servo driven dive-in type nozzles with its depth adjustments settings through HMI.

Fully automatic servo driven PFS tub opener and tyvek paper removing system can be offered optionally as per model selection.

Servo driven pick and place type plungering operation is done by pipe in – pipe out (tube vent) basis in case of aqueous liquid and vacuum assisted plungering is done when the liquid is viscous.

Precise filling and plunger insertion for dual-chamber prefilled syringes.

Fully automatic production control with intelligent testing devices at the core station , No friction between the contact surface of the plugger and the drug solution and the bottom rail during transport. The stopper is always protected by laminar flow, avoiding the risk of particles and contamination.

The main drive components of the syringe filling machine are servo-driven and are located in the lower part of the machine frame, which allows precise positioning and avoids pollution of the environment.

• The plastic PFS filling machine can be equipped with a servo motor-controlled filling pump for filling, which is highly accurate and easy to adjust.
• Configurable filling system CIP/SIP system.
• A nitrogen filling unit can be configured to isolate the medicinal solution from oxygen.
• Can be equipped with a vacuum filling system for filling the high viscous products.
• Configurable with Open-RABS isolation protection system and Class 100 air purification laminar flow system.

Plunger Rod Insertion and Self Adhesive (Sticker) Labelling Machines for Pre-Filled Syringes

Plunger rods are inserted with the help of pick and place system for proper placement and then syringe is labeled immediately on the same machine. The labeling dispenser on this machine is equipped with advance stepper motor for better accuracy.

Optional Accessories

• TTO Printer for printing batch details, barcode etc. on transparent/film labels
• Advance camera to inspect the printed batch details
• Computer system with SS stand to teach camera the parameters to inspect on labels
• Rejection mechanism to reject the PFS in case of no label on PFS, no printing on label and faulty printing on label
• FDA 21 CFR Part 11 compliance SCADA system with high end industrial touch screen and PC
• UPS for PLC, camera and PC