groninger implements a comprehensive concept for processing nested prefilled syringes

A new facility in Argentina that demonstrates the innovative capacity of the Crailsheim, Germany based company started production this year.

Sinergium Biotech, located in Buenos Aires, manufactures and processes successfully liquid pharmaceutical products. In addition to its own products, the company is also a licensee and importer of third-party products, which are filled on site in Argentina and processed for subsequent sale.

groninger’s expertise is not only restricted to the development, design and assembly of a customized processing line but extends far beyond that. groninger and Sinergium worked together to develop their own specific solution for product handling. The development of the corresponding machine solution is the result of comprehensive planning in the preliminary stages of the project.

groninger designed the complete manufacturing process right through to the prefilled and labeled syringes fitted with plunger rods. The overall project also included an inspection machine and integration of the final packaging equipment. Without the close cooperation of the Sinergium project management this would have been a difficult task.

Speaking of core competency, remember that groninger is one of the most innovative companies in the world in more fields than simply filling technology. This is made clear when considering the individual processing stages that groninger has implemented in the filling process. The process starts with unpacking the tubs, removing the Tyvek and foil coverings, and transport the syringes filled with the vaccine to the final packing process for further transport.

Laminar flow units and an oRABS guarantee compliance with the high requirements for product quality and production safety. The filling technology supplied by groninger processes the syringes and plunger stoppers ten at a time and has been specially designed for this product. A central component of the filling system are custom designed rotary piston pumps, which ensure a reliable and stable filling process.

The post-processing system uses a fully automatic plunger-rod insertion unit, which is fitted with electrical clutches for precisely reproducible limitation of the torque selected for screwing in the plunger rod.

The groninger labeling unit is equipped with a laser printer and a camera system for quality inspection of the print result. The integrated conveyor systems in the plant for the sorted syringes are designed to slow down the syringes automatically to prevent syringes from colliding and being damaged. The system can process up to 300 objects per minute.

The facility at Sinergium processes presterilized syringes, which are filled and closed on the filling machine, and also previously filled and closed objects, which are only subject to postprocessing. Sinergium Biotech has already completed an initial run for processing prefilled syringes. Noteworthy for the initial run is the line efficiency of more than 80%, which is a great number for an initial run and reflects the high quality of the training of the employees at Sinergium and also the reliability of the groninger systems.