Syntegon presents filling machine for small and micro batch liquid pharmaceuticals

15 Mar 2021 --- Primarily known for medium and high-performance lines, Syntegon Technology is now also bundling solutions for small and micro-batch pharmaceutical applications with Versynta FFP. 

The move follows a “noticeable shift” in the pharmaceutical industry – more high-priced biotech drugs for small patient populations require highly flexible filling solutions that achieve precise product yields at low output. 

Short for “Flexible Filling Platform,” Versynta FFP is an individually configurable machine with an integratable isolator for filling aseptic and highly potent liquid active ingredients. It can process up to 3,600 containers per hour and comes with 100 percent in-process control.

“Our complete portfolio covers the entire pharmaceutical equipment spectrum from clinical trials to large-scale production,” explains Crailsheim site manager Dr. Alexander Giehl. 

With a uniform operating concept and proven filling technology, Versynta enables the German packaging specialist’s partners to make “strategically scalable investments.” 

The first company to employ Syntegon’s new machine is Ferring Pharmaceuticals, an international pharmaceutical company.

Robots for safe transport
Versynta FFP can be easily converted to different container types such as vials, syringes and cartridges, as well as different filling systems, including single-use solutions. Instead of entire modules, only format parts need to be replaced, which Syntegon has also kept to a minimum. 

With Versynta FFP, Syntegon offers a combination of standardization, high modularity and short delivery times.In addition, the platform offers the possibility of vacuum-free high-potent vial processing. The Pharma Handling Unit, a four-axis robot developed by Syntegon, allows for safe and gentle transport. 

The robot transfers the containers from one station to the next without glass-to-glass contact. The laminar flow-optimized design ensures the airflow can reach the containers and flow around them without obstruction.

Going even smaller
Syntegon’s customers receive a lean and complete solution for the entire filling process from a single source, including an integrated isolator and ventilation technology. 

Versynta FFP is suitable for filling both aseptic and highly potent products with short cycle times. Pressure and zone concepts can be flexibly adapted. 

The Versynta portfolio is completed with Versynta microBatch, a solution for even smaller batches, which will be launched next year and is already being tested with a customer. 

“Maximum product yield and fast batch changes are even more important in micro batch applications. The biggest challenge was to design the production cell isolator without glove ports,” Syntegon’s senior product manager Klaus Ullherr explains. 

The result is a highly flexible and fully automated production cell with the smallest possible dimensions and a complete batch-to-batch changeover of less than two hours.

Last month, Syntegon shared details on its AI-enhanced pharma visual inspection system with PackagingInsights.

By Anni Schleicher