Robotic syringe filling system for sterile pharmaceutical production

For high-precision liquid dosing in sterile environments, this robotic filling system ensures accurate, contamination-free syringe, vial, and cartridge production with unparalleled efficiency.

Fills and Stoppers Syringes, Vials, and Cartridges

The Hull i-Dositecno RF Flex-Line Robotic-Syringe Filler System is an advanced fill-finish solution designed for pharmaceutical and life sciences applications. It employs precise Stäubli robotics for accurate transport and filling of syringes, vials, and cartridges in sterile, clean-ready SCF tubs, ideal for products like vaccines and insulin syringes. The system achieves a high throughput of up to 4,000 units per hour, maintaining stringent GMP, Annex 1, and 21 CFR Part 11 compliance with integrated IQ/OQ validation packages. Automation is streamlined via Siemens or Allen Bradley PLC-controlled servo motors, allowing for precise control over output rate and fill parameters. The equipment’s construction in premium stainless steel ensures durability and features such as an aseptic dosing system with peristaltic and rotary piston pumps for exceptional accuracy. Moreover, it supports complete line integration with other processing equipment, offers versatile configuration options, and includes a robust CIP/SIP for efficient cleaning and maintenance. The system is also engineered for minimal footprint and maximum access, ensuring ease of use and adaptability in high-speed, continuous production environments.

Benefits

  • Enhances production efficiency with up to 4,000 units per hour throughput.
  • Ensures product integrity and compliance with 100% in-process weight checks.
  • Minimizes contamination risk with cleanroom-ready, sterile operational design.
  • Offers flexible integration with existing production lines for seamless operation.
  • Reduces processing variability with precise servo-driven filling and stoppering.

General


Applications
Liquid formulations,Diagnostic kits,Injectables,Nasal sprays,Pharmaceuticals
End products
Insulin syringes,Chemotherapy injectables,Vaccines,Influenza nasal sprays,Antibiotic syringes,Covid-19 diagnostic kits,Antiviral liquid formulations,Hormone replacement therapy injectables,Allergy test kits,Decongestant nasal sprays
Steps before
Vial washing,Sterilization,Depyrogenation,Preparation of RTU components
Steps after
Capping,Lyophilization,Freeze drying,Packing,Product inspection
Input ingredients
syringes,cartridges,microvials,vials,SCF tubs,RTU components
Output ingredients
filled syringes,filled cartridges,filled microvials,filled vials,stoppered products,capped products
Market info

Technical Specifications


Accuracy
Exceptional accuracy and precision
Capacity
Up to 4,000 units per hour
Compliance
21 CFR Part 11 compliant
Compliance
cGMP compliant
Compliance
Annex 1 compliant
Automation
PLC-controlled
Filling method
Aseptic dosing system
Material
Premium stainless steel
Change parts
Syringes,vials,cartridges,microvials
Robot type
Stäubli Stericlean robot
Transport system
Servo-driven linear transport
Decontamination
Hydrogen peroxide compatible
Pick and Place
Up to 2-channel
Filling nozzles
Up to two nozzles

Operating Characteristics


Working mechanism
Robotic-assisted filling
Integrated steps
Filling,stoppering,capping
CIP/SIP
Available options
Batch vs continuous operation
Batch
Changeover time
Minimal due to flexible configuration
Automation level
Fully automated with PLC control

Material Compatibility


Cleanability
Yes
Corrosive resistance (e.g. acids)
Stainless Steel
Biological compatibility
Pharmaceutical-grade

Physical Characteristics


Compact footprint
Wall-mountable
Control panel type
Siemens or Allen Bradley PLC-controlled
Discharge method
Servo-driven linear transport
Construction Material
Premium stainless steel

Custom Options


Control panel type
Siemens/Allen Bradley PLC
Integration capability
Compatible with vial washers,sterilization tunnels,freeze dryer systems
Pick and place channels
Up to 2-channel for stoppers,tips,and caps
Nozzle configuration
Up to two filling nozzles
Footprint
Wall mountable
Compatibility with container types
Syringes,vials,cartridges,microvials
Cleanroom compatibility
Cleanroom ready