Nested syringe filling and stoppering line

Streamline your aseptic filling process with advanced machinery that handles nested syringe tubs efficiently, ensuring sterile conditions and precise operations from debagging to stoppering.

Prepares and Processes Nested Syringes and RTU Vials

The FREETUB Series by Marchesini Group is a pivotal component in the aseptic filling of nested syringes and ready-to-use vials. It automates the critical pre-processing steps such as tub debagging, de-liding, and de-lining, ensuring sterile environments and protecting sensitive biopharmaceuticals, vaccines, and pharmaceuticals.

Designed for integration into pharmaceutical and biotech production lines, it efficiently manages the handling of insulin syringes, prefilled epinephrine syringes, COVID-19 vaccines, and more. The system operates with both manual and automatic control options, providing flexibility across different production scales.

The FREETUB Series maintains sterility and precision with robust automation features, such as PLC control, automatic bag cutting, and robotized lid removal equipped with tear-proof mechanisms. It supports installation under various isolation technologies, including LAF, open RABS, closed RABS, or Isolator systems.

Engineered for meticulous sanitary standards, it allows manual intervention if necessary and includes mechanisms for tub rejection in case of faults. This equipment not only caters to high-throughput environments but also maximizes efficiency, thus meeting GMP and FDA regulatory standards.

Benefits

  • Enhances productivity by automating sterile preparation processes, reducing manual intervention and error rates.
  • Increases operational efficiency with versatile installation options under different isolator technologies.
  • Ensures product integrity with robotized handling that minimizes contamination risks during aseptic filling.
  • Meets stringent pharmaceutical standards with a design compliant with GMP and FDA requirements.
  • Offers operational flexibility with both automatic and manual control capabilities for varied production needs.

General


Applications
Rtu cartridges,Vaccines,Pharmaceutical syringes,Biopharmaceuticals,Ready-to-use (rtu) vials
End products
Insulin syringes,Rtu lyophilized vials,Rtu antibiotic vials,Measles vaccines,Covid-19 vaccines,Oncology drugs,Disposable syringe kits,Preloaded anesthetic cartridges,Prefilled epinephrine syringes,Hepatitis b vaccines
Steps before
Tub Debagging,De-liding,De-lining,Bagged Tubs Loading
Steps after
Nested Syringe Filling,Stoppering,Tub Unloading,Lid and Liner Disposal
Input ingredients
Bagged Tubs,Sealed Tubs,Nested Syringe
Output ingredients
Open Tubs,Debagged Tubs,De-lidded Tubs,Sterile Tubs
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


Automation
Manual / Automatic
Loading System
Manual and Automatic Options
Bag Disposal
Automatic
Lid Removal
Robotized with Tear-proof Movement
Tub Unload System
Positive Pushing System
Faulty De-liding Handling
Automatic Rejection / Manual Facility
Installation Environment
LAF / Open RABS / Closed RABS / Isolator

Operating Characteristics


Loading method
Manual/Automatic
Bag stretching station
Automatic
Gate operation
Automatic
Unloading system
Positive pushing without contact
Bag disposal
Automatic
Lid removal
Robotized system
Liner removal
Automatic
De-liding fault recovery
Manual facility
Tub orientation
Rotatable if necessary
Installation environment
LAF/open RABS/closed RABS/Isolator

Material Compatibility


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

Product type Characteristics


Container size
Standard nested syringe size
Container type
Nest / Tub
Material type
Plastic / Glass
Heat sensitivity
Sensitive
Viscosity
Low to high viscosity compatibility
Sterility requirements
Aseptic conditions
Stoppering type
Automatic / Manual
Stopper material
Rubber / Silicone
Automation level
Manual / Automatic
Nesting method
Pre-nested configurations
Sterile handling
Non-contact positive pushing

Physical Characteristics


Machine footprint
Compact
Feed/discharge method
Positive pushing system
Control panel type
Robotized system
Manual/Automatic operation options
Available
Installation environment
LAF,RABS,or Isolator

Custom Options


Control panel type
HMI / PLC
Integration possibilities
Open/Closed RABS,Isolator
Manual vs. Automatic operation
Manual/Automatic