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Dry powder filling machines

Powder antibiotics and other life-saving drugs demand absolute precision. Yet every gram of ultra-fine active ingredient can drift, contaminate or expose operators to potent compounds, turning “simple” filling into a high-risk, high-stakes process.

That’s where Syntegon comes in. Backed by 60 years of expertise and more than 250 dry powder filling machines in operation worldwide, we combine proven containment, accurate dosing, and easy-clean designs to safeguard your people, protect product quality and keep lines running at peak efficiency.

To learn more about our solutions, connect with an expert or download our brochures.

Connect with an expert Download our brochures

Our expertise

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Antibiotic powders for injection

Sterile powders are a common and important dosage form for active molecules that are not stable in an aqueous/liquid environment and cannot be marketed as ready-to-use injectables. Typical molecules in this category include beta-lactam antibiotics such as penicillin, cephalosporins, or acyclovir.

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Micro pellets

Spray-freeze-dried pellets are an innovative drug form. Sterile medicines are freeze-dried to very small but uniform balls. The main drivers of this promising lyophilization process: higher possible concentrated protein formulations, flexibility in mixing various pellets/spheres, as well as logistic advantages.

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Other sterile powders

Apart from antibiotics, there are further powders used for injection. Their formulation consists of drugs only or drug and excipient, both in a crystalline form. This dosage form is less cost-sensitive compared to directly lyophilized primary vials, since they require less energy and less infrastructure for aseptic production.

Your partner in powder filling since 1960

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Solutions for complete lines

Pure media are essential utilities in parenteral pharmaceutical manufacturing. From “cold” membrane-based systems for the generation of PW, HPW, and WFI and “hot” distillation-based systems for the production of WFI and PS, to the corresponding storage systems and distribution to the point of use, our portfolio provides a comprehensive and seamlessly integrated pure media infrastructure. For your drug product compounding needs, in turn, we also offer formulation systems. Comprising a wide range of process vessels and their automation as well as all associated peripherals including media supply and CIP/SIP units, our modular processing systems truly are “the perfect match for every batch.”

Benefits:

Generation, storage, and distribution of pure media
New: cold membrane process (MWFI)
Formulation systems for multiple process steps

Our formulation systems

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Sterility matters across the entire aseptic process – before, during and after sterile filling. Syntegon offers internal and external cleaning machines for vials and other containers. Once the vials have been pre-cleaned with Water for Injection (WFI), our HQL tunnel ensures safe and reliable sterilization and depyrogenation with dry heat. Following filling and capping, the vials can be transferred to our RAN external cleaning machine, which makes sure that no particles adhere to the outer sides of the vials; an important factor in protecting operators and healthcare workers. In addition we offer a vast portfolio of versatile sterilization solutions for an effective treatment of porous loads and liquids in open, semi-sealed or closed containers. The vacuum-steam, steam/air mixture and hot water shower processes support you in achieving reproducible equipment and terminal sterilization while optimizing your energy requirements.

Benefits:

Space-saving and flexible layout of cleaning machines
Cleaning with ultrasonic bath
Proven dry-heat sterilization with optimal tunnel design

Our cleaning machines

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Our vial filling systems combine flexibility and precision: a wide range of technologies, including auger dosing, pressure vacuum, or slide chamber dosing, make sure you can fill your products in a highly customized way. Tool-less format changes and filling stations with a variable number of filling heads increase the flexibility of your filling processes. Subsequent sealing offers you a variety of methods such as pick-and-place or continuous stoppering. Continuous capping with high speeds completes the safe and reliable closing process. 100 % in-process control (IPC) check weighing and inline inspection systems for empty vials, stopper position or crimp quality further increase product quality.

Benefits:

Modular machine set-up reduces production costs
Integrated inline inspection systems
Speeds up to 450 vials per minute, including 100 % IPC

Our vial filling machines

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Aseptic filling is all about product safety – and thus the separation of operators and pharmaceutical ingredients. Isolator technology helps to build this crucial barrier. Syntegon has established a comprehensive portfolio, including open RABS, closed RABS, containment and isolator systems. All solutions are tailored to customer requirements, from machine design and development to on-site installation and validation.

Benefits:

Integration instead of interfaces
Aseptic and high-potent applications
Rapid bio-decontamination cycles

Our barrier systems

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Inspection is a key quality safeguard for pharmaceuticals and contributes significantly to patient safety. It can also help to improve the entire production process. Our wide range of manual, semi and fully automated inspection machines inspects liquid and lyophilized pharmaceuticals for particles and container defects. Thanks to our long-standing inspection expertise, we offer state-of-the-art technologies for visual inspection and container closure integrity testing (CCIT), including high voltage leak detection (HVLD), static division (SD) and headspace analysis (HSA). During the filling process, inline inspection systems for empty vials, stopper position or crimp quality further increase product quality.

Benefits:

Stand-alone and inline inspection solutions
Camera-based and light transmission-based visual inspection
Cutting-edge, patented CCIT technology

Our inspection machines

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Automation (SODA/SCADA)

Efficient pharmaceutical production requires flexible equipment with robotic applications and comprehensive services. But that’s not all: making use and managing huge amounts of process data is just as important. Take our data acquisition solutions: they help you to reliably monitor and record crucial process data on both line and container level. SCADA (supervisory control and data acquisition) provides real-time machine and process data in one dashboard, thus enabling transparent line and batch control. SODA (single object data acquisition) fosters supply chain security by managing data for single containers, preventing time and cost-intensive incidents like complaints.

Benefits:

SCADA: detailed overview of all operations and processes
SCADA: recording and analysis of errors
SCADA: centralized access to individual machines and entire lines
SODA: risk reduction during production
SODA: traceability at container level

Our digital solutions

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The Syntegon company SBM (Schoeller-Bleckmann Medizintechnik) offers a vast portfolio of versatile sterilization solutions for an effective treatment of porous loads and liquids in open, semi-sealed or closed containers. The vacuum-steam, steam/air mixture and hot water shower processes support you in achieving reproducible equipment and terminal sterilization while optimizing your energy requirements.

Benefits:

Wide process range
Hygienic design
Flexible recipe editor for customized processes
Automatic in-line filter sterilization

Our sterilizers

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AFG 5000

The AFG 5000 is the innovation for filling and closing sterile powders in vials. It features a specially developed transport system that adjusts the speed during filling, weighing and stoppering to speed up the workflow. The 100 % in-process control (IPC) avoids any unnecessary product loss – an important advantage when producing cost-sensitive antibiotics such as penicillin or cephalosporins. Our highly flexibel AFG is available in several machine versions with different features and output rates from 160 up to 450 vials per minute.

Our solutions have got you covered

Size as a cost factor

Size as a cost factor

The larger the filling area of a machine, the higher the costs for containment, filtration, temperature control, operation, maintenance, and cleaning. Every centimeter or inch counts; especially in cleanroom class B, where powders are usually filled. We offer you a modular machine design that gives you the flexibility to choose between different filling and weighing modules, which provides further space savings.

Variable transport for optimal speed

Variable transport for optimal speed

Speed is important in pharmaceutical production, especially in the antibiotics market. Our AFG 5000 processes up to 450 vials per minute.

Air supply and hygiene in the filling area

Air supply and hygiene in the filling area

Processing powdery pharmaceuticals is a challenging task. Dust-tight barriers and a sealed air supply are essential.

Service Agreements

Service Agreements

Find out more about our Service Agreements here.

Digital Solutions

Digital Solutions

Find out more about Digital Solutions here.

Parts

Parts

Find out more about Parts here.

Maintenance

Maintenance

Find out more about Maintenance here.

Technical Support

Technical Support

Find out more about Technical Support here.

Modernizations

Modernizations

Find out more about Modernizations here.

Training

Training

Find out more about our Training here.

Expert Services

Expert Services

Find out more about our Expert Services here.

Dry powder filling downloads

Trend article on powder filling

Trend article on powder filling

Insights into maximum safety and efficiency during filling

How has the market for antibiotics changed?

How has the market for antibiotics changed?

Interview with our expert Markus Heinz

Interested in dry powder filling machines?

Interested in dry powder filling machines?

Talk to a Syntegon expert to learn more about dry powder filling machines.

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