COP/COC syringe filling line – PFS filling machine

COP/COC and PFS prefilled syringes

The prefilled syringes used on these lines fall into two main categories:

• PFS COP/COC luer lock, designed in highly pure cyclic polymers (COP/COC). Generally available in 0.5 to 5 mL, they are fitted with a luer-lock interface and a rigid cap. These polymers are sterile and perfectly suited to SC or IV administrations. They also stand out for their low extractables profile and excellent mechanical resistance. As a result, their unbreakable nature makes them a preferred choice for sensitive biopharmaceuticals. Their main limitation remains a higher cost compared with traditional glass.
• Safety PFS, available in glass or COP/COC polymers, in formats ranging from 0.3 to 2.25 mL. Their safety mechanism, supplied individually sterile, is adapted to SC/IM administration, particularly for vaccines or emergency situations. This design improves the prevention of exposure accidents but may introduce increased handling complexity and additional cost.

All of these containers ensure full compatibility with aseptic filling modules. In particular, their controlled dimensions support exact positioning. In addition, their controlled rigidity protects against deformation. Finally, their design, intended for luer-lock systems, simplifies integration into automated filling lines.

Applications and industrial sectors

COP/COC syringes and safety PFS are widely used across various pharmaceutical applications:

• SC, IV, or IM injectable drugs;
  • Single-dose or multi-dose vaccines;
  • Biotechnology products sensitive to glass–product interactions;
  • Advanced therapies, high-viscosity solutions, or processes requiring enhanced aseptic conditions;
  • Hospital environments, emergency services, vaccination campaigns, and biopharmaceutical production units.

The stability of these containers ensures consistent protection of medicines. Additionally, their low risk of breakage minimizes product loss. Their controlled sterility further guarantees maximum safety. For these reasons, industries increasingly choose them as a standard for drug administration.

Operating principle of the machine and the aseptic filling line

An automated aseptic filling line for prefilled syringes follows a rigorous process. First, it denests and transports the containers with precision. Next, it performs the filling operation before crimping or completing the closure. The system then inspects each syringe to ensure quality. Finally, the containers are reintegrated into a protected flow to safely continue production. EREA Pharma systems incorporate smooth mechanical motion to limit mechanical stress while ensuring stable repositioning of PFS.

The PFS filler provides fine control of micro-volumes thanks to high-precision dosing modules suitable for sensitive solutions. Laminar flow and containment barriers ensure sterility throughout the entire process.

The line accommodates both COP/COC syringes and safety PFS. It also integrates modular tooling to process multiple formats. As a result, it supports low-volume presentations as well as those requiring enhanced reproducibility.

To better meet your needs for integrating COP/COC containers or safety PFS, we can conduct a dedicated technical study. This assessment determines the configuration best suited to your industrial requirements, ensuring a fully optimized solution for your aseptic filling line.