Syntegon has introduced its new MLD Advanced filling machine, expanding its portfolio for ready-to-use (RTU) nested syringes and targeting the pharmaceutical industry’s growing demand for high-throughput, precision-controlled processing.
The machine is engineered to handle up to 400 syringes per minute, offering 100% in-process control (IPC) while maintaining the aseptic integrity of each unit. The system incorporates automatic bag and tub openers, along with a no-touch transfer mechanism that preserves sterility as syringes enter the filling zone.
“Especially with high-value medicines, it is essential that each drop is filled and weighed optimally,” said Markus Burkert, Product Manager at Syntegon. “That’s why we have combined the MLD platform, which was previously used primarily for cartridges and vials, with our technologies for syringe filling.”
The machine integrates Syntegon’s Pharma Handling Unit, which denests syringes without glass-to-glass contact, aligning them through a pitch adjustment station before securing them in specialised transport clips. According to Burkert, “This unique clip system is the first key feature we adopted for syringe applications from the cartridge line.”
He added, “The special circulating transport system ensures smooth transportation and is therefore ideal for RTU syringes, as well as vials and cartridges.”
Before filling, each empty syringe is weighed using 100% IPC, ensuring exact dosing and complete documentation. Filling and stoppering follow Syntegon’s FXS series protocols, with filling needles mounted directly to the Pharma Handling Unit—enabling flexible redosing if required.
Post-filling, the stoppering process is executed via vacuum or vent tube methods, and containers are then returned by the circulating transport system to the Pharma Handling Unit, which re-nests the syringes with precision.
The company states that its integrated approach delivers a streamlined and reliable process for handling presterilised syringes, offering pharmaceutical manufacturers a single-source solution for complex aseptic operations.
