FULLY AUTOMATIC PFS MACHINE

Manual Bucket Placement (Optional / Can be Automated Later)

• Operator places the bucket at the entry conveyor. (Future scope: Vision-guided robotic bucket placement.)

Fully Automatic Paper Removal

• A robotic arm (preferably 4 or 6-axis) equipped with a vacuum gripper or soft suction pad:
• Identifies paper location via vision sensor or fixed positioning. Picks and removes the protective paper sheet from the syringe tray.Transfers and discards it in a designated bin.
• (This eliminates human involvement at the Glow Pot Location.)

Automated Tray Handling

• Pick-and-place system or SCARA robot picks the syringe tray from the bucket and places it on the filling table.

Stoppering with Pipe In-Out Technology

• 5-track vibrator bowl feeding system for stoppers
• Pipe In-Out Stoppering system places plungers accurately into syringes

High-Accuracy Filling

• Peristaltic pumps/Rotary Syringe controlled by servo drives perform the filling operation with ±1% accuracy.

Additional Automation (If applicable):

• Vision Inspection (plunger presence, fill level, cosmetic defects)
• Online Rejection System
• Tray Re-arrangement and Exit Conveyor

Benefits of Full Automation:

• Zero human touch after bucket placement
• Improved batch consistency and compliance
• Enhanced sterility and GMP validation
• Reduced operator fatigue and labor dependency
• Shorter cycle time and higher productivity

Frequently Asked Questions

What kind of stoppering systems do you offer?

We offer "Pick and Place Type" and "Vacuum Chamber Type" stoppering systems, based on the specific requirements of your production process.

Can the machine be configured with LF, RABS, or an Isolator?

"Yes", the machine can be configured with Laminar Flow (LF), Restricted Access Barrier Systems (RABS), or an Isolator, depending on your operational and regulatory needs.

What functions are covered in the fully automatic version?

The fully automatic version includes "nest paper removal, filling, and stoppering", all managed through advanced robotic motion. This automation minimizes human intervention and maximizes efficiency.

What is the difference between the semi-automatic and fully automatic versions?

In the "semi-automatic version", after the filling process, the operator manually places the nest in the vacuum chamber for stoppering. In the "fully automatic version", all processes, including nest handling, filling, and stoppering, are fully automated and controlled by robotic systems.

What kind of filling methods do you use?

We use highly accurate "Peristaltic Pump" or "Rotary Syringe" filling methods, selected based on the customer's User Requirement Specification (URS).

What is the filling accuracy of the machine?

We provide a filling accuracy of "±1%" of the filled volume. For example, if you are filling 2ml, the variation will be within "±0.02ml".

What is the filling volume range the machine can handle?

The machine is designed to handle various filling volumes, customizable based on specific production needs.

How many heads are available, and what is the production speed?

The machine can be configured with "2, 5, or 10 heads, depending on your production requirements, with speeds ranging from ""4500 to 10000 syringes per hour".

What types of syringes can the machine fill?

The machine is versatile and can fill a wide range of pre-filled syringe types, including both standard and custom-designed syringes.

Can the machine be integrated with SCADA systems?

Yes, the machine supports integration with SCADA systems and is fully compliant with 21 CFR Part 11, ensuring adherence to global regulatory standards.

What kind of maintenance is required for the machine?

Routine maintenance includes regular checks of moving parts, calibration of filling mechanisms, and cleaning. We recommend scheduled servicing by qualified technicians to ensure optimal performance.

Is there a warranty for the PFS machine?

"Yes", the machine comes with a comprehensive warranty, which covers parts and labour for a specified period, providing long-term reliability and peace of mind.

Can the machine be customized to meet specific production requirements?

"Yes", we offer a range of customization options to meet your specific needs, including different stoppering systems, filling methods, and automation levels.