Aseptic filling machine for pre-filled glass syringes
Aseptic filling machine for glass prefilled syringes – The performance of a filling line first depends on full control of the container. This is precisely why glass prefilled syringes have become the benchmark for sterile single-unit packaging. They offer high dosing accuracy and proven safety, while ensuring perfect compatibility with aseptic environments. Today, two formats dominate the market: glass PFS with staked needle and glass PFS with luer-lock connection. Each format meets specific industrial requirements and provides advantages tailored to pharmaceutical needs.
Customised Technical Solution
Static and Dynamic Protection
Rapid Installation and Implementation
Easy-to-clean Surface
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Characteristics of glass prefilled syringes (PFS)
Type I glass PFS ensure excellent stability for sensitive injectable formulations, thanks to their chemical inertness and limited interaction potential. Staked-needle models cover volumes from 0.3 to 5 mL and include the integrated needle, needle shield, plunger, and stopper. Intended for SC, IM and IV administration, they are widely used for vaccines, anticoagulants and biotherapies. Their main advantage lies in their ready-to-use format, guaranteeing precise dosing; however, their limitations include the presence of silicone and a potential particle-shedding risk that may affect certain proteins.
Luer-lock syringes, also made of Type I glass, are available from 0.5 to 10 mL. With their luer-lock tip and closing cap, they ensure a secure connection, particularly suitable for diluents and biological products administered IV or SC. Their versatility is a major strength, despite the absence of an integrated needle and potential risks of incorrect fixation during improper handling.
These standardized characteristics allow ideal integration into a modern aseptic filling line, ensuring container integrity, efficient nest management, and overall process optimization.
Pharmaceutical applications and relevant sectors
Glass prefilled syringes are widely used across vaccines, biotherapies, anticoagulants, diluents and other sensitive injectables. Their sterile, single-unit packaging makes them essential in GMP environments, where minimizing manipulation and securing the filling chain are critical.
Their compatibility with critical formulations and their ability to reduce contamination risks make them reliable solutions. Furthermore, the robustness of their closure systems reinforces their position as preferred containers. They are therefore widely used in pharmacy, bioproduction, radiopharmacy, and advanced therapies.
Robotic aseptic filling line for glass PFS
The robotic aseptic filling line developed by EREA Pharma is designed for full compatibility with glass PFS, whether staked-needle or luer-lock formats. The process begins with automated denesting. Next, volumetric or gravimetric filling ensures high precision. The plunger is then inserted in a controlled manner, with continuous monitoring of critical parameters.
This robotic architecture ensures:
- Maximum dosing accuracy
- A significant reduction in human intervention
- Controlled mitigation of particulate risk
- Strict compliance with GMP requirements
- Full traceability of operations
The entire process enhances safety, repeatability and pharmaceutical-grade quality in aseptic filling.
Combining an aseptic filling machine for glass prefilled syringes with robust PFS containers delivers a high level of performance and safety. You may contact the company for a technical evaluation or a tailored proposal. A personalized quotation will then be provided.
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