One-stop Prefilled Syringe Machine Manufacturer in China
Designed specifically to meet the stringent requirements of the pharmaceutical industry, the prefilled syringe machine from SaintyCo combines precision filling with automatic stoppering, sealing and online testing in one machine to guarantee swift, sterile and reliable production without interruptions.
We have applied advanced servo control technology and laminar air protection to our syringe pump, not only to guarantee accurate dosage of each syringe, but also to ensure stable and high efficient performance for your work.
The prefilled syringe machine is suitable for both glass and plastic syringes, and is the choice for vaccines, biomaterials, insulin, and other injections meeting your needs form small batch up to commercial production.
SaintyCo provides professional after-sales service and the best customization so that your production efficiency and product quality can be improved, making your product more competitive.
What is Prefilled Syringe Machine
Designed specifically to meet the stringent requirements of the pharmaceutical industry, the prefilled syringe machine from SaintyCo combines precision filling with automatic stoppering, sealing and online testing in one machine to guarantee swift, sterile and reliable production without interruptions.
Prefilled Syringe Machine Components
Commonly, the equipment offers polycarbonate safeguard cabinets and 304 stainless steel tubing structures for higher durability and cleanability in GMP areas.
High-precision quantitative filling is generally achieved using ceramic plunger pumps. Sterile filling zone and contamination-free is fully secured by providing facility of aseptic zones, integrated with sensitive detection systems and laminar airflow units.
Other vital elements also include fill heads, individual servo drives, discharge catch pans, vacuum chambers, and pneumatic actuators adding to make the result perfect and credible.
Last but not least, electrical panels, AC drive, and PLC & HMI interface come in one control system to achieve accurate control, real-time monitoring, and fully meet the pharmaceutical industry automation planning.
Benefits of Prefilled Syringe Machine
The use of pre-filled syringe production equipment can achieve high-precision quantitative liquid medicine filling, guarantee the consistency of dosage for each syringe and cooperate with the laminar flow system and aseptic environment to prevent contaminant effectively and ensure the safety of products.
The extremely automatic control system will save you a lot of time and decrease your work intensity. The process is easy, and it does not need to be processed by many workers, so the cost of production is reduced.
Meanwhile, the prefilled syringe machines can help to shorten production cycle, meet the flexible batch production according to market demand, reduce the production cost for your company, to shorten the production cycle, and to improve the market competitiveness of products, and achieve the safety and reliability of patients ‘ medication.
Features of the Prefilled Syringe Machine
High Precision Filling
Pre-filled syringe machines are commonly provided with servo-driven piston systems or peristaltic pumps to accurately and repetitively fill syringes. SaintyCo machines may get a very close filling tolerance, ±1% % or even less.
Sterile Operating Environment
SaintyCo’s prefilled syringe filling machine can be used in a Class A clean room. It’s installed a Laminar Flow Hood (LAF) or an isolator system working on the principle of isobaric, for microbial-free. SaintyCo also provides CIP/SIP systems for efficient in-place sterilization.
All-around Automations
The prefilled syringe fillers have modules for filling, plugging, sealing, labeling, and testing, which simultaneously create the integrated line. SaintyCo adopts it to be able to accomplish the entire process from feeding to finished product discharging automatically, so as to minimize manual work.
Fit for different syringe types.
The prefilled syringe machines can be adjusted for glass or plastic prefilled syringes from 1ml to 20ml. They usually also come with a versatile mold hanging system for switching to various specifications for your project.
Super High Speed And Super Productivity
Production can be up to 200-600 pieces per minute according to the configurations. This makes it excellent for commercial/industrial high-capacity production.
Online Rejection and Detection System
The SaintyCo system constantly checks important quality parameters as liquid level, sealing integrity, the presence of bubbles, and impurities. Any variances are immediately exposed, and defective piecesare taken out on a regular basis to keep the highest quality for your business.
Combined with Various Drugs
SaintyCo prefilled syringe filling machines are perfect when dealing with medications that need high sterility and products that are sensitive to active ingredient degradation. Furthermore, they can be combined with aseptic freeze-drying and downstream packaging lines for a completely sterile process.
Simple to use and friendly interfaces
The prefilled syringe machines from SaintyCo use the PLC & touch screen control system. Additionally, our system also provides support for parameter memory and batch traceability. This feature of the system constantly monitors the system, detecting faults automatically, sounding the alarm in time.
The Main Structure of Prefilled Syringe Machines
Syringe Infeed Unit
Pallet conveyor structure
SaintyCo prefilled syringe machines are often integrated with servo servo-driven piston system or peristaltic pumps, which guarantee the reliability and accuracy of the fill volume for each syringe. SaintyCo’s equipment is capable of having an extra-tight filling tolerance—±1% % or better.
Positioning mechanism
Precise positioning and stability of the syringes are ensured by the positioning mechanism. It is usually adjustable to accommodate your various syringe designs.
Detection sensor
The detection sensor is the key structure to achieve automatic control and quality assurance. It is able to detect the working conditions of the equipment online, guaranteeing the position of six syringes.
Filling System
Filling pump module
The filling pump module can measure the liquid, meanwhile it can guarantee the accuracy and the sanitation. USUALLY: SaintyCo uses various filling pumps to accommodate different liquids, wear-resistant, compatibility, no inclusions(No bubbles, no impurities), high viscosity, strong corrosion, or other biological agents.
Filling needle
To meet the specific guiding requirements for liquid filling and control liquid flow routes, the filling needle is particularly crucial. It is the highest level of assurance for aseptic filling and may eliminate bubble formation.
Liquid level control
The precise control of the liquid level ensures steady dosing and prevents overfilling or underfilling.
Stoppering System
Piston/Rubber Stopper Feeder
The piston stopper feeder may partition the piston into large packages and then convey them in series. It is capable of retraining the piston in the same direction.
Stopper device
The stopper device is supplied with stoppers from the piston/rubber stopper feeder., capable of sucking the piston into the syringe opening by means of vacuum adsorption, mechanical push or cylinder pressure.
Pressure plug detection
The pressure plug detection is a key inspection stage that verifies that the rubber stopper or piston is successfully inserted into the syringe by monitoring pressure or vacuum response during stoppering.
Aseptic Zone
Laminar Air Flow, LAF
LAFs make a major contribution to the sterility of the production area; in fact, they are capable of achieving air cleanliness up to ISO 5 / Grade A.
HEPA filter
The HEPA filter can remove airborne particles and microorganisms to obtain clean airflow for LAF units or isolator systems.
RABS or Isolator System
The main role of the isolator system is to create very good and very controlled physical isolation around vital aseptic areas.
Sealed housing made of stainless steel
A stainless steel sealed casing system was designed in order to protect the critical components inside it, preserving a sterile atmosphere for you.
Inspection Module
Weighing system
This weighing system is used for correctly detecting filling dosage and discharge of unqualified products.
Leak test system
The leak test system is applicable to detect leakage of the syringe seal, to prevent leakage and pollution, so as to ensure production security and compliance.
Outfeed System
Collection device
You are able to reuse the finished syringes in an organized, controlled manner from the collection device. You are also able to keep the product in good shape by cushioning and protection.
Product rejecter with defective product feature
The bad product elimination device is used for automatically identifying bad products, is convenient and fast to use and can guarantee product quality and safety for you.
Control Panel
PLC control system
PLC control system, control the filling machine so that the filling machine can coordinate work, the various parts match.
HMI touch screen interface
- The touch screen HMI interface is simple and easy for operators to use to start, stop, adjust and monitor the equipment running status.
Servo motor drive system
The servo motor drive system (Servo motor driven system) is a very important part of the machine mechanics. The filling and other filling movements are all driven bya servo motor. The main advantage of the servo motor is, on the one hand, it can control the filling dosage accurately, the other hand, servo motor can provide more stable filling speed, better filling accuracy.
Pneumatic system
Compressed air is used as the power to make the reciprocating movement of the mechanical both steady and rapid, the parts, such as filling, plugging, are also forced to be moved left and right or rotate because of the design of the way of air press.
How do you categorize a Prefilled Syringe Machine?
Degree of Automation Classification
Fully Automatic Prefilled Syringe Machinery
Fully automatic machines can complete filling, piston inserting, sequence sealing, labeling, and inspection in one process. Being highly efficient, accurate, and operator-independent, they are suitable for large-scale industrial manufacturing.
Semi-Automatic Prefilled Syringe Machines
Semi-automatic machines need component of a manual reliance as in the direction of loading, filling syringes, or seals. They provide an alternative to costly toolmaking when short batches, pilot productions, and R&D or industrial line extension are required.
Manual Equipment
Manual tools, a few manual machines are in use today, except in small or medium-sized enterprises where automation is not possible or cost-effective.
Classification According to the Filling Method
Piston Pump Filling Machine
Piston pumps can be utilized for filling of prefilled syringes. They use mechanical pistons to provide the same volume of fluid every cycle and are known for their accuracy and ease of maintenance. For general use, they are often the least expensive and most reliable choice for your projects.
Ceramic Plunger Pump Fillers
If your product needs to be filled with high filling accuracy and is highly corrosive, especially with sensitive or aggressive chemicals, ceramic piston pumps are a great choice. They are commonplace tools of high-end injectable production, in which precision is vital for your projects.
Peristaltic Pump Filler
Peristaltic pumps are used for biologics in particular. Since the fluid touches only disposable tubing, its risk of contamination is minimized. This is often the route pharma companies will take when sterility is chief among their concerns.
Pressure Filling Machine
One of the less common but not less important types of filling machines is the pressure filling machine. They regulate flow in pressurized systems and are used only where traditional pumping systems will not work.
Category by Applicable Type of Syringe
Glass Syringes Filling Machines
The glass syringe filling machines need to be cleaned and sterilized very well to guarantee product safety and to permit high-temperature treatments.
Devices for Plastic Prefillable Syringes
These machines are dedicated to processing plastic (polymer-based) syringe barrels in a fragile manner, consisting of avoiding deformation during filling, as well as sealing.
Syringe Filling Machines for Special Applications
Specialty Syringe Filling Needle Types, Formats, or Drug Delivery Gear machines are customized for off-standard syringe concepts and support optimization of the pre-fillable syringe delivery system.
Use of the Prefilled Syringe Machines
Vaccine Filling Line
The filling process of vaccines need to be kept highly sterile. The technologies are predominantly based on ceramic plunger pumps and peristaltic pump systems, as these operate with precision and without any contact with contamination. These lines usually have vision inspection devices to check proper product integrity.
Insulin Filling Line
Lines for filling insulin require dependable, constant operation and high batching output with high dosing precision. Fully automated prefilled syringe lines are generally desirable because they can meet these demands efficiently.
Biologics
Biologics filling demands very careful products handling in order to maintain the products integrity, especially for the fragile molecules. Reducing shear force during filling is important, so peristaltic pumps and gentle filling systems are ideal here.
Conclusion
Prefilled syringe machines are engineered to fill sterile liquids into syringes with high precision while maintaining a contamination-free environment. Widely used in the pharmaceutical industry, they are particularly well-suited for handling vaccines, biologics, and protein-based drugs. Consistent dosing accuracy is one of their core strengths, ensuring reliability in critical applications. For tailored solutions or further details, feel free to reach out to the SaintyCo team.