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    Annex 1 environmental monitoring with fewer interventions

    Reduce operator interventions and repeated stops for settle plate changes to stabilize machine availability.

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    Environmental monitoring for Grade A sterile fill

    Grade A viable air monitoring for the full duration, 4-hour plate exposure limits and CCS-based placement of viable and non-viable points raise pressure on aseptic environmental monitoring.

    As your strategic lifecycle partner, Syntegon conducts a site-specific risk assessment and automates passive or active and passive viable monitoring with SPC 2000 and SPC 4000 to reduce operator interventions and stabilize availability.

    Regulatory compliance, proven automation, real-time detection

    How to benefit from long-term microbiological expertise?

    Apply risk-based monitoring knowledge to every machine project.

    How to reach a higher automation degree with proven technology?

    Automate passive or active and passive viable monitoring with SPC 2000 and SPC 4000.

    How to detect deviations faster with real-time monitoring?

    Monitor viable and non-viable particles continuously during aseptic production.

    Find the right environmental monitoring solution for your line

    Overall 4 Solutions
    Monitoring mode
    Handling concept
    Integration fit
    Manual intervention impact
    Change interval or runtime
    Retrofit or deployment scope
    Data and traceability
    Benefits
    spc-2000
    SPC 2000
    Monitoring mode
    Passive viable monitoring
    Handling concept
    Magazine and gripper automate settle plate exchange
    Integration fit
    Isolators and RABS
    Manual intervention impact
    Manual interventions reduced by 80%
    Change interval or runtime
    Minimum 24-hour plate exchange interval
    Retrofit or deployment scope
    New machine or retrofit across all brands, types and controls
    Data and traceability
    Standardized exposure data transfer, optional barcode scanning
    Benefits

    Best if you want:

    • Automate passive viable monitoring in existing aseptic lines
    SPC_4000_front_solo
    SPC 4000
    Monitoring mode
    Active and passive viable monitoring
    Handling concept
    Magazine and gripper automate settle plate and air sampling head handling
    Integration fit
    Isolators and RABS
    Manual intervention impact
    Manual interventions reduced by approx. 95%
    Change interval or runtime
    Minimum 24-hour plate exchange interval
    Retrofit or deployment scope
    New machine or retrofit across all brands, types and controls
    Data and traceability
    Standardized exposure data transfer, optional barcode scanning
    Benefits

    Best if you want:

    • Combine active and passive monitoring in one system
    mhd-robot-detail
    Robot-Assisted Viable Air Sampling
    Monitoring mode
    Active viable air sampling in the process zone
    Handling concept
    Robotic positioning of the air sampling head during production
    Integration fit
    Aseptic production environments
    Manual intervention impact
    Reduces manual sampling access in the process zone
    Change interval or runtime
    Defined by sampling schedule
    Retrofit or deployment scope
    Dependent on-site configuration
    Data and traceability
    Sampling data transferable to higher-level systems
    Benefits

    Best if you want:

    • Automate active air sampling with robotic positioning 
    Biofluorescent-Particle-Counter
    Biofluorescent Particle Counter
    Monitoring mode
    Real-time viable and non-viable particle detection
    Handling concept
    Continuous airborne particle sensing with no plate handling required
    Integration fit
    Aseptic production environments
    Manual intervention impact
    No routine plate changes required
    Change interval or runtime
    Continuous operation during production
    Retrofit or deployment scope
    Dependent on-site configuration
    Data and traceability
    Real-time particle data with in-shift deviation signals
    Benefits

    Best if you want:

    • Detect deviations in-shift without retrospective plate reads 
    Featured_Download_Teaser_SettleplateChanger4000

    See how SPC 4000 automates plate handling

    Download to see how SPC 4000 automates active and passive viable monitoring.

    • Combine active and passive monitoring
    • Cut manual interventions by approx. 95%
    • Increase availability by up to 300 h/year
    Download

    Environmental monitoring built for longer running production

    microbatch-mbf

    Robotized plate handling in gloveless isolators

    Automate monitoring in a gloveless robotic production cell.
    spc-2000-square

    One system for active and passive viable monitoring

    Cover both monitoring modes with one handling unit.
    alf-5060

    Real-time detection of viable and non-viable particles

    Identify microbial and non-viable particles continuously during production.
    Flyer_SPC_2000_2 (1)
    Highlight Topic

    Settle Plate Changer footprint

    The SPC requires minimal space and provides a compact, space-saving solution for your passive viable monitoring process.

    Request your free footprint templates to check the space requirements in your specific machine.

    In addition to the standard configurations, other layouts are possible after consultation with us.

    Contact us

    Your strategic lifecycle partner for environmental monitoring

    service-life-cycle
    Ready for everything, from start to routine

    From installation to optimization, Syntegon supports you with structured service packages, training, and specialists – for safe, stable and resilient production across the lifecycle.

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    service-life-uptime
    Secure availability – every day

    Fast spare parts, qualified support and preventive maintenance help you avoid unplanned downtime, protect performance and keep daily operations reliable.

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    service-future-ready
    Make your line fit for tomorrow

    Scalable retrofits, data solutions and handling/automation systems help you adapt to new demands, improve OEE and keep your lines future-proof across changing requirements.

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    Environmental Monitoring knowledge hub

    SPC 2000 flyer
    SPC 2000 flyer

    Learn how automated passive EM cuts interventions and improves availability in aseptic lines.

    Download
    SPC 4000 flyer
    SPC 4000 flyer

    See how one system combines active and passive viable monitoring with fewer interventions.

    Download

    Frequently asked questions

    Sedimentation plates may be exposed to cleanroom air for a maximum of 4 hours. In running production, that means the machine must stop every 4 hours for a manual plate change unless handling is automated. Repeated stops increase contamination risk and reduce machine availability.

    SPC 2000 automates passive viable monitoring. SPC 4000 automates active and passive viable monitoring in one system. Both integrate in isolators and RABS, support lockable and non-lockable lids, and are available with new machines or as retrofit solutions across all machine brands, types and controls.

    Automated plate handling replaces repeated manual settle plate changes during production. SPC 2000 and SPC 4000 extend change intervals to a minimum of 24 hours and stop only for magazine changes. Both increase machine availability by up to 300 hours per year.

    Yes. SPC 2000 and SPC 4000 are available as retrofit solutions for all machine brands, types and controls. Both also offer standardized interfaces for exposure data transfer, and barcode scanning is available as an option for stronger traceability.

    Biofluorescent particle counters use advanced sensors to detect fluorescence emitted by biological particles when exposed to specific wavelengths of light. That enables continuous detection and differentiation of viable and non-viable airborne particles during production without relying on retrospective plate reads.

    Consider one system when the process requires both active and passive viable monitoring. SPC 4000 combines both modes in one robotic handling unit inside isolators and RABS and reduces manual interventions by approx. 95%, supporting a stable and reliable monitoring process during production.

    Interested in automating your viable monitoring process through the Settle Plate Changer?

    Interested in automating your viable monitoring process through the Settle Plate Changer?

     

    Request a quote.

     

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