Bulk vial liquid filling system

Ensure reliable and efficient processing of critical biopharmaceutical and pharmaceutical liquids, like vaccines and monoclonal antibodies, with our advanced vial filling system designed for high-speed, precise operations in sterile environments, adaptable to both small-batch and large-scale production needs.

Fills and Seals Vials for Liquid Pharmaceuticals

The FLC 3000 from Syntegon is designed to efficiently fill and seal vials in liquid pharmaceutical production lines, particularly for high-demand products like Covid-19 vaccines and monoclonal antibodies. Its compact GMP-compliant design supports a wide filling range of 0.2 to 500 milliliters and achieves throughput of up to 600 vials per minute, reducing changeover times with only three format part sets required. The machine’s peristaltic pump technology ensures precise dosing while maintaining sterility, and it integrates seamlessly into production environments with options for full in-process control. A clean and hygienic design facilitates easy maintenance and operator safety, meeting stringent GMP and FDA requirements. The FLC 3000 can be customized with additional filling technologies and systems as needed, providing robust support for both batch and continuous operations.

Benefits

  • Maximizes output with speeds up to 600 vials per minute.
  • Ensures precise dosing and sterility to maintain product integrity.
  • Streamlines production with minimal changeover times due to three format part sets.
  • Meets GMP and FDA standards, ensuring regulatory compliance.
  • Integrates easily into existing systems, supporting both batch and continuous operations.

General


Applications
Pharmaceutical liquids,Liquid formulations,Vaccines,Oncology preparations,Pharmaceutical containers,Biopharmaceuticals,Pharmaceuticals
End products
Trastuzumab injection,Insulin vials,Monoclonal antibodies,Covid-19 vaccines,Chemotherapeutic agents,Antiretroviral syrups,Liquid biologics,Ready-to-use vials,Sterile saline solutions
Steps before
Washing,Depyrogenation,Inspection
Steps after
Closing,Crimping,Inspection,Capping,Tray Loading,Sterilization
Input ingredients
bulk vials,RTU vials,pharmaceutical liquids,biopharmaceuticals,Covid-19 vaccines,oncology preparations
Output ingredients
filled vials,sealed vials,safe pharmaceutical products,inspected pharmaceutical products
Market info
Syntegon is known for its expertise in processing and packaging technology, offering innovative solutions for the food and pharmaceutical industries. It has a strong reputation for advanced equipment, sustainability, and customer-oriented service.

Technical Specifications


Speed
Up to 750 vials/min
Capacity
600 vials per minute,36,000 vials/hour
Filling Volume
0.2 to 500 ml
Automation
Inline inspection systems
Machine Design
Compact GMP-compliant
In-process Control (IPC)
100%
Scalability
Small to large production batches
Changeover Time
Minimal
Operation Output
Up to 200 containers/min
Footprint
Small
Flexibility
Multiple filling technologies
Inspection Type
Visual,Inline
Filling Method
Combi filling platform

Operating Characteristics


Filling speed
600 vials/min
Filling volume
0.2–500 ml
Output capacity
up to 36,000 vials/hr
Automation level
PLC-controlled
Batch vs. continuous operation
Batch operation
Changeover time
Minimal
CIP/SIP
CIP available
Cleaning method
CIP
Inline inspection solutions
Stopper position,crimp quality
Cross-process solutions
KIV tracking and identification
Portability
Mobile (for FLT 1000)

Material Compatibility


Density/particle size
0.5–2.5 g/cm³ / 50–1000 µm

Physical Characteristics


Compact footprint
Yes
Discharge method
Volumetric / gravity
Control panel type
Touchscreen
Machine footprint
Small / mobile platform
Filling volume range
0.2 to 500 ml
Filling speed
600 vials per minute
Compact GMP-compliant design
Yes
Single or multiple filling technologies
Perialistic pump / Combi filling

Custom Options


Control panel type
PLC / HMI
Integration possibilities
SCADA / ERP Integration
Machine design
Compact GMP-compliant
Automation level
Manual / PLC / SCADA
Discharge method
Inline / Manual
Transport system
Precise sensitive handling
Retrofitting capabilities
Multiple fill technologies