Syntegon unveils advanced line concept for liquid pharmaceutical filling

GERMANY – At Pharmatag 2025, Syntegon introduced a new line concept for liquid pharmaceutical filling, engineered to optimize performance, ensure high product yield, and reduce human intervention.

The innovation, developed in collaboration with pharmaceutical industry partners, aims to meet the growing demand for sterile, high-speed, and contamination-free drug manufacturing.

At the heart of the new system is SynTiso, a line concept featuring a gloveless isolator that enables greater automation and minimizes operator involvement.

“But we go one step further,” says Markus Heinz, Product Manager at Syntegon. “The robots are generally located as far away from the process as possible and are only used for aseptic setup and when needed.”

This layout aligns with Annex 1 regulatory requirements and adheres to the First Air principle, which ensures uninterrupted airflow in the aseptic zone.

By distancing the robots from the critical areas, the design reduces particle generation and contamination risks.

Real-time monitoring of germs and particles also eliminates the need for settle plate exchanges, further streamlining cleanroom protocols.

A key feature of the SynTiso system is its contactless, suspended transport system, which generates virtually no particles and simplifies cleaning and maintenance—even when handling highly potent drugs such as oncologics.

According to Syntegon, the system enables faster aseptic transport and up to 50% shorter batch changeovers within a more compact footprint.

The line supports speeds of up to 600 syringes, vials, or cartridges per minute, with 100% in-process control (IPC).

In parallel developments, Syntegon recently expanded its pharma and food packaging portfolio. In April, the company launched the MLD Advanced, a high-speed filling machine tailored for ready-to-use (RTU) nested syringes.

With output capabilities of up to 400 syringes per minute, the MLD Advanced integrates aseptic, no-touch transfer with a pitch-adjusted, clip-based circulating transport system originally developed for cartridge lines.

Each syringe is weighed pre-filling using 100% IPC, and the filling-stoppering process builds on the proven technology of Syntegon’s FXS series.

“Especially with high-value medicines, each drop must be filled and weighed precisely,” noted Product Manager Markus Burkert.

Additionally, Syntegon introduced the FGCT count feeder for cookie packaging at the iba trade fair, emphasizing gentle yet efficient high-speed handling to reduce product damage during packaging.

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