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Maker - Product Challenge

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Changemakers

Injectables Filling Equipment

After being used to contain the blood of martyrs after death or to store the anointing oil of French monarchs, today ampoules are the first choice in packaging injectables. You create ampoules by melting the glass tube into the desired shape and seal them at the neck by melting the top of the glass tube. The only way for you to extract the contents from an ampoule is by breaking the glass at its breaking point, making it perfect for single dose applications only.

Ampoules

The word parenteral comes from Greek and means outside the intestine (para=outside and enteron=intestine). In fact, when it comes to parenterals, we are referring to those dosage forms that are administered directly into the bloodstream using a hypodermic needle, avoiding going through the gastrointestinal tract. Using parenteral filling equipment, parenteral solutions are placed in containers such as vials, syringes, or ampoules.

Parenterals

Pharmaceutical cartridges are glass containers of cylindrical shape, suitable for liquid or solid pharmaceutical dosage forms. Generally, these are designed for a specific apparatus such as pre-filled syringes and autoinjectors. Drugs that can be placed in cartridges using a pharmaceutical cartridge filling equipment include insulin, dental anesthesia, and other emergency drugs for allergies.

Pharmaceutical cartridges

A pre-filled syringe or PFS is a single-dose disposable syringe that is supplied loaded with the substance to be injected. By using a pre-filled syringe filling machine, you can have excellent dosage accuracy due to the exact filling of medications. During administration, safety from potential contaminants is also ensured as they are directly injected after opening. To further minimize the risk of contamination, pre-filled syringes are often filled and sealed in a sterile environment using stainless steel equipment.

Pre-filled Syringes

“How clean does my equipment needs to be?” That's what manufacturers often wonder about in order to meet the high sterilization standards the pharmaceutical industry demands. Lending manufacturers helping hand have been single-use bags, also known as disposable, first introduced in the late 1990s. They immediately gained popularity because they reduce the risk of cross-contamination, minimalize cleaning and sterilization demands, and require a low capital cost.

Single-use bags

Some of the vaccines in use today were originally developed decades ago. But advances in research, expertise and vaccine development equipment provide immunizations from bacterial and viral diseases (antibodies and cell therapy) to more people every year. The Covid 19 pandemic highlights the urgent need to scale up the production of vaccines and ensure an automated as well as reproducible manufacturing environment.

Vaccines

During crime scene investigations in any movie, you've probably seen forensic scientists collecting evidence and biological samples in small containers. Here, these are the vials, used to store medicines, especially in liquid form, or laboratory samples. Often made of glass or plastic, vials can be labeled as single-dose vials or sterilized and reused more than once. They are also available with various closure systems depending on the material and storage requirements.

Vials

If you've ever heard the acronym WFI spoken, know that we're not talking about wireless technology to connect your computer. WFI stands for water for injection, a sterile water used as a solvent to dilute other solutions for injections to the body. Traditionally, WFI was only produced through the distillation process using water for injection equipment until other methods such as reverse osmosis, electrodeionization, and ultrafiltration were developed.

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Water for injection

romaco-macofar-micromaxx-datasheet-pdf

Romaco-Macofar-Micromaxx-datasheet.pdf

Insulin is a hormone that controls blood glucose levels produced by the beta cells in the pancreas. As a medication, insulin was discovered by Frederick Banting and Charles Best in 1921, for which Banting was awarded a Nobel Prize in 1923. The insulin production process involves manipulating the biological precursor to insulin and cultivating it inside bacteria using specialized technology.

Insulin

A dishwasher tablet is an essential detergent. It consists of a pressed mixture of sodium and potassium salts, surfactant, fragrance, and other filler agents, mixed with the help of tablet making machines. The products’ use in America and Europe is high, unlike in the Asian continent, where the price limits its usage. Its global market size will reach $990 million in 2026 from $475.6million in 2019, according to Grand View Research forecasts.

Dishwasher tablets

Chewable tablets are suitable for patients who have difficulty swallowing. Chewable tablet formulation masks the natural flavors of pharma drugs and alters their aftertaste. But besides the taste, chewable tablets favor the bioavailability of pharmaceutical ingredients.

Chewable tablets

The fizz of effervescent tablets is commonly associated with a vitamin C boost. But the soluble pill is an excellent drug delivery method for pediatric and geriatric patients. Sometimes referred to as carbon tablets, manufacturing effervescent tablets binds biocarbonate and citric acid that produce the smooth hiss as they dissolve in liquid.

Effervescent tablets

When taking a tablet, it is usually the job of our stomach to break down the medication to make it ready to be absorbed into the bloodstream. However, some drugs are not meant to be dissolved in the stomach because the acidic pH of the stomach can disintegrate the drug, making it no longer effective. Using tablet coating equipment that applies a polymer barrier to the tablet makes it possible to protect it from stomach acidity.

Enteric Coated Tablets

Microtablets range between 1 and 4 millimeters, making the dosage form an excellent delivery system in polypharmacy. The size of the products makes them easier pills to swallow, but microtablets production brings a unique set of complexities.

Microtablets

Multilayer tablets are a popular fixed-dose combination (FDC) offering a range of release profiles for effective drug delivery. Multilayer tablet technology solves challenges to API consistency, allowing manufacturers to develop formulations from incompatible ingredients while optimizing the release profile for immediate release and controlled release.

Multi-layer tablets

The wave of liquid soaps and detergents in the 1950s revolutionized home and personal care. Cheap and convenient, these off-the-shelf products fit perfectly into the lifestyle of the time. A few decades later, though, plastic waste put the sustainability of hygiene products into question. Refill tablet production technology answers that by eliminating single-use plastic. Instead of picking up a new bottle every time, end-users complete the formulation process in a multi-use container and with a simple instruction: just add water.

Refill tablets

It is strange how two tablets can belong to the same but at the same time to a different category depending on how the tablet itself is classified. For example, chewable tablets and effervescent tablets have two different routes of administration but both belong to the category of uncoated tablets. Uncoated tablets are prepared by compression of granules in which no coating is added after compression. They may be single-layer or multi-layer tablets.

Uncoated tablets

There are slight differences between human and animal pharmaceuticals, but that dissimilarity is enough to create new production challenges. Veterinary tablets formulation reflects the diversity of enzymes that different species use to break down substances. Although the methods involved are comparable to human drug manufacturing, equipment and processes need to adapt to a wider dosage variability in veterinary tablets.

Veterinary tablets

The two-piece capsule is a visual shorthand for all types of medical remedies. Advances in technology have made the production of hard-gelatin capsules a convenient delivery method for drugs and other ingested substances. But the simple solution requires micrometric precision to be manufactured to the proper pharmaceutical standards.

Hard gelatin capsules

The nonproprietary name for HPMC – hydroxypropyl methylcellulose – is such a mouthful that it has two abbreviations. Hypromellose is the other one. The non-ionized material offers a safe alternative to gelatin capsules, especially as most common API and excipients are suitable HPMC capsule ingredients.

HPMC capsules

Softgel capsules fast-track the delivery of medication to the bloodstream. Unlike solid pills, they do not need to be broken down by the body before the drugs can be absorbed. Moreover, they are optimal vehicles for oils and fat-soluble formulations that cannot be compressed into tablets.

Softgel capsules

API making equipment must observe rigorous quality control standards across the entire manufacturing process. The pharmacodynamic properties of active pharmaceutical ingredients API make them highly sensitive to their environment, making API manufacturing and production a tightly regulated field.

Active pharmaceutical ingredients (API)

The click and puff of inhalers is a universal signal for respiratory conditions. Inhalers quickly grew into preferred drug delivery systems for asthma and COPD. Dry inhaler powder formulation produces a more stable drug than liquid dosage forms. Moreover, inhaler ingredients are more resistant to bacterial growth.

Dry inhaler powder

Slim table top structure

Linear transport system

Suitable for both high speed powder filling and high speed liquid filling

Easy assembly and disassembly of dosing disc from machine front side

Use of brush less servomotor technology

Aseptic filling equipment is crucial for sensitive products, as they need to be filled into their primary packaging in an environment free from contamination caused by harmful bacteria, viruses, or other microorganisms. Choosing an aseptic filling solution requires consideration of the physical form of the product, the type of primary packaging, the volume to be dosed per package, and the production speed. Aseptic fillers are widely used for cleaning, filling, and sealing pre-sterilized vials, cartridges, ampoules, and syringes in the pharmaceutical industry. Aseptic filling is also used in the food industry to process for example, dairy products that need harmful bacteria's minimized, or ensure shelf-stable products that do not require refrigeration. In these industries, aseptic equipment is integrated into the production line for maximum isolation and sterilization. And, can either be configured as an automated or manual process, depending on standards that the products require.

Aseptic filling equipment

Micro dosing systems

Sterile Filling Solutions

Pharmaceutical

Filling lines

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

Connect directly with world leading manufacturers of filling lines equipment and find technology to build or improve your production line.

Filling - Making.com

Filling Lines Equipment - Making.com

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

Parenteral preparations refer to drugs using non-oral means of administration. Injectables, such as needles and syringes, are used to deliver a drug into the systemic circulation directly in the veins, muscles, under the skin, or in the tissue.

These parenteral formulations are pharmaceutical dosage forms that have strict regulations on being sterile, pyrogen-free, and free from visible particulate matter including reconstituted sterile powders. Solutions, suspensions, emulsions, and gels with APIs intended for administration by injection are usually supplied in vials, ampoules, pre-filled syringes, or pens to facilitate ease of use.

Injectables

Liquid

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

Packaging

Continuous

At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with chemicals or hazardous substances since they can be potentially dangerous to human health.

Packing

liquid

solid

The Romaco Macofar MicroMaxX is an aseptic injectable vial filling machine that offers mechanical speeds ranging from 6,000 to 24,000 vials per hour.

Fill up to 24,000 vials per hour with pharmaceutical powders or liquids under aseptic conditions. High speed sterile vial filling with 100%

High-speed aseptic injectable vial filling machine - Making.com

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The marketplace for finding innovative production technology

Making.com

steriline_robotic-nest-filling-line_rnfm-pdf

STERILINE_Robotic-Nest-Filling-Line_RNFM.pdf

Wide range of options to suit your exact requirements

Suitable for use with all available nests

High capacity, up to 18,000 pcs/h

Huge flexibility thanks to wide range of options

Engineered to meet or exceed all relevant cGMP, GAMP and 21CFR Part11 requirements

Bag filling equipment is a crucial component in many industries where products need to be packaged efficiently and quickly. Whether you're filling bags with powder, granules, or other materials, automated bag fillers can streamline the process and save time and labor costs. Bag fillers often come with additional features, such as stickers or other labeling equipment, to add branding or product information to the bags. This can save time and money by eliminating the need for separate labeling equipment.

Bag Filling

Single-use technologies are increasingly being used in the biotech industry due to lower costs, lower risk of cross-contamination, flexibility, and convenience. A single-use bioreactor uses disposable bags instead of a culture vessel to carry out the bioprocess. Using disposable bags, instead of reusable bioreactors, can help reduce the setup time and the time between production cycles. It also reduces sterilization demands for vessel reuse, leading to significant cost savings. In addition to single-use bags, single-use sensors are also employed for efficient and low-cost bioprocessing. Single-use applications are especially suitable for the production of biopharmaceutical products.

Single use systems

Volumetric dosing systems

Chemical

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

Process

When looking for capping equipment, it is crucial to know first which type of capper your product requires. Do you want screw caps, twist-off caps, hand pumps, or push-pull caps on your bottle or container? If you require different cap types for format changeover times can be time-consuming. The bottle cap seals the top opening of a bottle to guard the product against leakage and spoilage and sterility and filling requirements depend on the nature of your product.

Capping

Increasingly, pre-sterilized Ready To Use (RTU) nested vials, cartridges and syringes are the preferred packaging option for modern pharmaceuticals.

Nested syringe filling machine - Making.com

https://making-tst.imgix.net/2018/10/Steriline-673_Robotic-Nest-Filling-Line.jpg

steriline_robotic-vials-filling-machines_rvfm-pdf

STERILINE_Robotic-Vials-Filling-Machines_RVFM.pdf

Complete aseptic vial filling solution using robot technology

Fast throughput of up to 6,000 pcs/h

“No rejection” design reduces valuable product wastage to near zero

Engineered for extended duty cycles and minimum maintenance downtime

Fully cGMP, GAMP and 21CFR Part11 compliant.

Current and future developments in pharmaceuticals increasingly rely on aseptic production methods, particularly involving cutting-edge gene and cell

Aseptic automatic vial filling machine - Making.com

https://making-tst.imgix.net/2018/10/Steriline-_Vial-filling-machine_RVFM.jpg

steriline_filling-machines_vfm-pdf

STERILINE_Filling-Machines_VFM.pdf

Continuous, high accuracy filling of vial, cartridges and syringes

Nitrogen purge of vessels before, during and after filling maintaining quality

Small form factor and linear layout reduces downtime for maintenance or changeover

Can operate at up to 24,000 pcs/h

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

The volume filling of vials, cartridges and syringes is a vital part of the production of a wide range of pharmaceuticals. Traditionally, high-accuracy

Vial filling machine - Making.com

https://making-tst.imgix.net/2018/10/Steriline_Vial-filling-machine_VFM200.jpg

printable-sheet-specifications-mi-i-pdf

printable-sheet-specifications-MI-I.pdf

holds up to 4 heads

can handle lyo stoppered vials

integrated weighing and quality control

easy sterilization using H2O2

uilt to cGMP and FDA standards

R&amp;D

Batch

The essential objectives of containment systems are personnel protection and preventing the release of toxic or infectious material into the environment. Containment is also used to prevent a product or sample from contamination by the external environment. In the chemical and pharmaceutical industries, containment solutions are used to protect the personnel from the leaking of airborne particles of hazardous substances, as powders or liquids are handled or transferred during processing.

Containment

The i-Dositecno MI-I is specially designed for sterile pharma filling, able to fill sterile liquid and powder in doses from 1 to 500 mls into vials

For smaller-scale production of vials and syringes for the injectables market, sterile conditions and accurate metering are still required for filling,

Start-up sterile filling line for injectables - Making.com

https://making-tst.imgix.net/2016/09/MI-I-001.jpg

rota-verpackungstechnik-general-brochure-pdf

ROTA-Verpackungstechnik-general-brochure.pdf

Eyedrops processing is quite literally a sight for sore eyes. There is no shortage of eye care products, from eyewashes to anesthetics to antibiotics. But formulating eyedrops is a complex affair with multiple safety checkpoints. Technological advances bring a pair of fresh eyes to manufacturing, ensuring higher-quality products for specialized applications.

Eyedrops

Adheres to the highest safety levels

Renown process reliability

Easy and quick change-over

Customizable to your specific needs

Cannabinoids are natural compounds obtained from the Cannabis sativa plant. Delta-9-tetrahydrocannabinol or THC is a psychotropic substance. Cannabidiol, or CBD, is non-psychotropic and often used for nutraceutical purposes. Cannabinoid equipment extracts THC and CBD from the plant and prepares the substance for formulations that treat pain, nausea, anxiety, and inflammations. Cannabinoids are processed in various forms, including creams, capsules, and oils.

Cannabinoids

Ampoule filling machine are the perfect containers to store parenteral fluids and their filling demands best possible sterile conditions.

Filling ampoules or vials with parenteral fluids are an essential matter for which you need to consider the highest levels of safety and reliability in

Ampoule filling machine - Making.com

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Around a third of your natural protein composition is collagen. But the human body still finds good use for more of it, whether to reinforce joints or aid digestion. Collagen powder processing breaks the chains of amino acids into smaller units, allowing them to be consumed at higher concentrations without changing your diet.

Collagen powder

Curry powder

Cocoa minus its fats makes cocoa powder. Deriving this culinary element follows a careful process of roasting and winnowing cocoa beans before the nibs are ground, generating a liquor. The butter that results from melting fats is removed to leave the ingredient that defines recipes from brownies to a Frostbite cocktail.

Cocoa powder

Chili powder

Baking powder is perhaps the best-known secret of baking. The leavening agent forms bubbles in dough and batter to give muffins, cakes, and no-yeast pizza their tempting lift. First developed in the 19th century, baking powder production turned baking into the home activity we know today.

Baking powder

Looking beautiful is hard work. Queen Elizabeth I knows this well. Just think she used so many cosmetics and makeup containing toxic materials, especially lead-based face powder, that she even died from them. Today fortunately, you no longer need lead to make face powder. Simply mix pigments, fillers, dry and wet binders, and compress the mixture using a powder compacting press. Then the face powder is ready to be applied using a powder puff.

Face powder

The fishmeal powder market forecast shows that its global market value will reach USD 10.3 billion by 2025. Expanding since 2019, at an annual growth rate of 6.5%. Fishmeal powder production has strong business potential with the increase of applications in animal feed, pet food, and fortified foods.

Fishmeal powder

Food powder is the result of drying and pulverizing food. It has been around since the astronauts when out to space. Fruits have a short shelf life and are difficult to preserve due to their high water content.  Fruit powder processing allows you to keep the nutrients of the fruits for a longer time, even off-season.

Fruit powder

In 1682, Denis Papin found a method to remove collagen from animal bones, discovering gelatin. But it was the inventor Peter Cooper who developed gelatin powder processing. In 1845 he secured his invention with US patent 4084 for a dessert of gelatin powder called “portable gelatin”.

Gelatin powder

Forged metal objects appear seamless, simple items. But as the use of metals changed over time and constructions became more intricate with additive manufacturing, a new way of processing materials surfaced. Metal powder manufacturing replaces the classic blacksmithing techniques, reducing scrap waste in the meantime. The final metal products, however, retain that shiny allure of the archetypal metal pieces.

Metal powder

Basically, to make milk powder, you need to remove the water content from the liquid milk and turn it into powder. How to do it? After pasteurizing and homogenizing the milk, milk’s water content is removed through filtration, evaporation, and drying. You have then to cool and sieve it before filling the containers. Here's how you get milk powder.

Milk powder

Powder detergent is one of the most widespread washing solutions used in the laundry of fabrics. Since they contain no water, powder detergents are lighter than liquid detergent or pods, which results in cheaper transport and, thus, a more affordable choice for the end consumer. Although manufacturers can formulate their powder detergents differently, the detergent powder production process relies on a combination of builders, surfactants, and enzymes.

Powder detergent

It took the scientific community almost 70 years to agree on the name ‘protein’ and discard the popular alternative, proteid. But protein powder processing still needed another five decades to be commercialized in the 1950s. Once extraction and purification could be industrialized, protein powder soon became a basic staple supplement.

Protein powder

Everything tastes like porridge, the saying goes. That may be an exaggeration, but in theory, reaction flavors could make everything taste the same. Thankfully, flavorists and chemists in the flavor industry are more inventive than that, and colorful process flavors treat our taste buds to a broad palette of sensations, flavors and aromas.

Injectables Filling Equipment

Which injectables filling technology do you need?

High-speed aseptic injectable vial filling machine

Nested syringe filling machine

Aseptic automatic vial filling machine

Vial filling machine

Start-up sterile filling line for injectables

Ampoule filling machine

Aseptic filling machine for liquids and powders

High-speed small volume liquid filler

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