Filling and stoppering system for nested syringes

Ensure aseptic precision in syringe and vial preparation with a high-speed filling system designed for seamless integration and contamination prevention.

Fills and Stopper Nested Syringes and Vials

The Extrafill 10 by Marchesini Group is a high-speed, automated filling and stoppering machine specifically engineered for the pharmaceutical and biotech sectors. It excels in aseptic processing for liquid formulations, handling a range of container formats including nested syringes, vials, and cartridges. The machine employs a ten-head filling system with brushless motor-driven movements, ensuring precise dosing and reducing the risk of contamination thanks to its Balcony Style design, which promotes optimal airflow. Unique features such as the piston and peristaltic pump interchangeability, alongside in-process weight control, enhance operational flexibility. Capable of processing up to 36,000 syringes per hour, the Extrafill 10 integrates seamlessly into production lines with its denesting and detraying units, along with reject and recover systems for faulty containers. Compliance with GMP standards is ensured, with options for installation under LAF, RABS, or in isolator environments, offering a high degree of process control and contamination prevention. Additionally, the system facilitates efficient maintenance access and format changes, vital for minimizing downtime in high-demand environments.

Benefits

  • Enhances production efficiency with high-speed processing up to 36,000 syringes per hour.
  • Minimizes contamination risks through optimal airflow design and aseptic processing capabilities.
  • Reduces operational downtime with easy format changes and maintenance access.
  • Ensures precise dosing with adjustable weight control and interchangeable pump systems.
  • Meets stringent pharmaceutical standards with compliance options for various controlled environments.

General


Applications
Liquid formulations,Syringes,Vials,Biopharmaceuticals,Cartridges,Pharmaceuticals
End products
Insulin prefilled syringes,Biotech protein formulations,Antibiotic vials,Saline syringes,Adrenaline auto-injectors,Monoclonal antibody solutions,Heparin cartridges,Growth hormone cartridges,Vaccine vials,Chemotherapy liquid doses
Steps before
Washing and Sterilizing,Air Cleaner and Blowing,Nested-Tray Preparation
Steps after
Visual Inspection,Syringe Re-nesting,Alu-capping,Packaging
Input ingredients
nested syringes,RTU vials,RTU cartridges,Nest/Tub,Nested-Trays,Tub/Nest
Output ingredients
filled syringes,filled vials,filled cartridges,stoppered containers,sealed products
Market info
Marchesini is renowned for manufacturing high-quality packaging machinery for the pharmaceutical and cosmetics industries, offering innovative, customized solutions with advanced automation and technology.

Technical Specifications


Speed
up to 36,000 syringes/h
Filling Heads
10
Filling Volume
0.5 ml - 10 ml (syringes),2R - 15R (vials),1 ml - 5 ml (cartridges)
Automation
Brushless motors
Weight Control
0 รท 100% Adjustable IPC
Stopper Sorting System
Innovative system to avoid jamming
Sampling
Dedicated unload lane
Machine Installation
Possible under LAF,open/closed RABS,or Isolator
Container Rejection
Single container rejection system
Denesting/Detraying Unit
Robotized for syringes and RTU vials
Dosing Method
Rotary Piston Pumps / Peristaltic Pumps
Container Type
Syringes,RTU vials,RTU cartridges

Operating Characteristics


Automation level
Manual / PLC / SCADA
Batch vs. continuous operation
Batch / Inline Continuous
Airflow Laminarity
Perfect air flow laminarity over containers
Wall installation arrangement
Backside maintenance access
Stopper sorting system
Innovative to avoid jamming
Changeover capability
Easy switch between pump types
Container rejection system
Single container rejection
Feeding system efficiency
Sticky stoppers recovery system
Installation flexibility
Under LAF,open/closed RABS,Isolator

Physical Characteristics


Machine type
Automatic High-speed Filling Machine
Filling heads
10 filling heads
Footprint
Balcony Style Design
Installation
Possible Wall Installation
Product formats
Syringe,RTU vials,RTU cartridges
Product types
Liquid to very viscous gel
Stopper sorting system
Innovative system to avoid jamming
Control type
Brushless motors
Rejection lane
Single Container Rejection
Sampling lane
Dedicated unload lane for sampling
Container diversion
Integrated system for vial to alu-capping machine

Custom Options


Integration possibilities
No Glass-To-Glass connection to downstream machines
Installation arrangement
Wall Installation with backside maintenance
Stopper sorting system
Innovative system for simpler format change