Lower risk, more agility, better product protection
How vaccine manufacturing connects across the line
Start with the right formulation setup
Upstream decisions shape later flexibility. Syntegon connects formulation, storage and transfer concepts so teams can compare batch setups such as 150 l and 600 l and supply vial filling with fewer process interruptions.
Build contamination control into fill-finish
Barrier strategy defines sterile operations. Syntegon helps compare isolator lines and RABS upgrade concepts, including integrated 100% in-process control and contained transfer points.
Protect sensitive products during cold filling
Sensitive vaccine products require stable conditions from thawing to closure. Syntegon defines low-humidity isolator concepts that enable filling at 2 to 8 °C and helps protect active substance integrity.
Keep capacity available across vial formats
Portfolio shifts should not leave line capacity unused. Syntegon plans for fast format changes, multi-format vial handling and retrofit paths that adapt existing lines to new vaccine requirements.
Use parallel processes to keep output moving
Freeze-drying can tie up capacity for days. Syntegon designs line concepts that keep liquid filling productive in parallel and where the application fits, can reach up to 600 vials per minute
Connect inspection, cleaning and downstream steps early
Line performance depends on more than filling alone. Syntegon helps align outside washing, inspection and packaging interfaces early so the full concept works as one integrated system.
Start with the right formulation setup
Upstream decisions shape later flexibility. Syntegon connects formulation, storage and transfer concepts so teams can compare batch setups such as 150 l and 600 l and supply vial filling with fewer process interruptions.
Build contamination control into fill-finish
Barrier strategy defines sterile operations. Syntegon helps compare isolator lines and RABS upgrade concepts, including integrated 100% in-process control and contained transfer points.
Protect sensitive products during cold filling
Sensitive vaccine products require stable conditions from thawing to closure. Syntegon defines low-humidity isolator concepts that enable filling at 2 to 8 °C and helps protect active substance integrity.
Keep capacity available across vial formats
Portfolio shifts should not leave line capacity unused. Syntegon plans for fast format changes, multi-format vial handling and retrofit paths that adapt existing lines to new vaccine requirements.
Use parallel processes to keep output moving
Freeze-drying can tie up capacity for days. Syntegon designs line concepts that keep liquid filling productive in parallel and where the application fits, can reach up to 600 vials per minute
Connect inspection, cleaning and downstream steps early
Line performance depends on more than filling alone. Syntegon helps align outside washing, inspection and packaging interfaces early so the full concept works as one integrated system.
Explore the complete line
See how flexible vaccine fill-finish works in practice
What makes a vaccine line concept effective?
IDT Biologika scales high-speed vaccine vial filling
Aspen expands vaccine filling in less than 6 months
Janssen Vaccines gains flexibility for shifting batch needs
AJ Vaccines upgrades aseptic filling without full replacement
Vaccines knowledge hub
AJ Vaccines Case Study
Learn how AJ Vaccines future-proofed its line with a RABS-update from Syntegon.
Aspen Pharmacare vaccine vial line case study
See how Aspen Pharmacare expanded sterile vaccine vial capacity with a Syntegon vial filling line designed for multiple formats ensuring high quality.
Bavarian Nordic: Award-winning fill and finish project
Explore how Bavarian Nordic combined cold filling, isolator protection and parallel processes.
IDT Biologika high speed vial filling line case study
See how IDT Biologika scaled production to 80 to 100 million 2R vials per year with a high speed line, isolator and 100 % IPC.
Janssen Vaccines: Flexible filling for future drug launches
Learn how Janssen increased batch flexibility with a tailored formulation and storage setup.
Interested in Vaccine manufacturing?
Our experts will be happy to talk you through the process personally.
News
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