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Ampoule filling machines

Ampoules require precise handling at every step from cleaning to sealing. But tight timelines, strict compliance and fragile containers make reliable processing a constant challenge for pharma manufacturers.

Syntegon meets this challenge with ampoule lines designed for gentle handling, accurate dosing and secure flame sealing. From small to large batches, we tailor each solution to your setup, integrating seamlessly with upstream and downstream systems.

Curious how this could work in your facility? Talk to a Syntegon expert for tailored advice or download our brochure to explore proven solutions in action.

Connect with an expert Download our ampule brochure

Complete pharmaceutical ampoule processing line featuring formulation, sterilization, filling, and inspection systems, including an integrated ampoule filling machine for aseptic drug production.

Solutions for complete ampoule lines

Close-up of an ampoule filling machine performing high-precision sealing with flame technology, ensuring sterile closure of pharmaceutical ampoules in aseptic environments.

Opening station for closed ampoules

When it comes to bioprocessing, the systems from Syntegon’s subsidiary Pharmatec flexibly support the production of small and large volume parenterals (SVP/LVP) and infusions (IV). The process solutions comprise modular set-ups of temperature-controlled stainless-steel tanks that can be assembled to meet customer-specific settings. The new, cost-efficient SVP Essential is a fully automated, ready-to-use system to produce simple parenterals such as analgesics, insulin, and generic drugs.

Benefits:

Adaptable to specific room conditions and floor plans
Continuous process monitoring for the highest possible safety
Suitable for toxic substances up to OEB5 in isolators
SVP Essential: less engineering effort, faster delivery times

Our formulation systems

Pharmaceutical formulation system with stainless steel vessels and automated processing, designed to support sterile drug preparation ahead of ampoule filling machine operations.

Before and after filling, vials, ampoules, syringes, and cartridges require thorough internal and external cleaning to remove residues and contaminants. This step is key to protecting operator and patient safety. Syntegon’s compact cleaning systems cover low to high output ranges and support efficient, hygienic processing.

Designed for a wide range of containers, the systems focus on fast, user-friendly operation with ergonomic design.

Benefits:

Nearly complete surface cleaning
Use of various cleaning agents
Integration into Syntegon barrier systems possible

Our cleaning machines

Stainless steel pharmaceutical equipment for automated cleaning of glass ampoules, integrated into the sterile processing line before ampoule filling machine operations.

Reliable container pre-treatment is essential for product safety when filling liquid pharmaceuticals into ampoules, vials, bottles, cartridges, or syringes. Syntegon offers a wide range of depyrogenation tunnels and sterilization technologies for effective, energy-efficient treatment of open, semi-sealed, and closed containers. Methods include dry heat, vacuum, steam/air mixture, and hot water shower sterilization.

Our sterilization & depyrogenation tunnels

Pharmaceutical-grade sterilizing tunnel for depyrogenation of glass ampoules, ensuring sterile conditions prior to ampoule filling machine integration in aseptic processing lines.

Our filling systems for pre-sterilized packaging offer flexibility and precision through various technologies like valve piston, peristaltic pump, mass-flow, and time-pressure filling. Tool-less format changes and adjustable filling heads enhance adaptability, while versatile sealing options such as gas burning or vacuum stopper insertion ensure secure container closure. In-process control (IPC) continuously monitors fill weight and stopper position for consistent quality.

Benefits:

Precise, customizable filling
Combi filling available
Integrated barrier systems (RABS, closed RABS, isolator)

Our filling systems

Precision ampoule filling machine with integrated closing station, designed for sterile pharmaceutical production and accurate liquid dosing in aseptic environments.

Ampoules require reliable inspection to ensure patient safety. Syntegon offers manual to fully automated systems for detecting particles and container defects in liquid and lyophilized products, using visual inspection and advanced CCIT like HVLD, static division, and headspace analysis. Inline systems enable real-time defect detection.

Benefits:

Up to 36,000 units/hour (AIM series)
Camera and light transmission inspection
Patented CCIT technology
Modular design for fast setup
Inline detection for higher safety

Our visual inspection machines

Automated inspection system for glass ampoules, ensuring quality and compliance after processing by the ampoule filling machine in pharmaceutical production lines.

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

Pharmaceutical sterilizer chamber for component sterilization in aseptic processing, supporting upstream operations of the ampoule filling machine in sterile drug production.

ALF 4000

The ALF 4000 combines ease of use with high output, filling and closing 1–30 ml ampoules at up to 30,000 containers per hour. Its linear, indexing-motion design ensures gentle handling and precise filling with various systems. The simplified design allows easy retrofitting and excellent access for maintenance and cleaning.

Benefits:

Ideal for wall-mount and isolator installation
Optional combo version for ampoules and injection bottles
Minimal format parts for greater efficiency

ALF 5000

The ALF 5000 offers three high-output configurations, processing up to 36,000 ampoules or vials per hour. It handles open or closed containers—or both on the combi platform. With an optimized pharmaceutical design, easy accessibility, and hygienic, low-contamination operation, it sets a benchmark in high-performance filling.

Benefits:

Easily convertible combi filling system
Gentle handling with carrying rake transport
Seamless integration into barrier systems
Optional filling systems with 4 to 12 filling points

The ALF 4000 and ALF 5000 from Syntegon enable fast, reliable filling and closing of ampoules and injection vials – with flexible integration and minimal format parts. Designed for modern production environments, they offer efficient, compliant processes. Contact our experts or download our brochure to learn more.

Connect with an expert Download our ampoule brochure

Our solutions have got you covered

Automation

Take our data acquisition solutions: they help you reliably monitor and record critical process data at both line and container level. SCADA (Supervisory Control and Data Acquisition) provides real-time machine and process data in a unified dashboard, enabling transparent line and batch control, faster decisions, and improved performance.

SODA (Single Object Data Acquisition) manages data at the individual container level, enhancing traceability and supply chain security. By identifying issues early, it helps prevent time-consuming and costly incidents like complaints, recalls, or compliance risks.

Safety and versatility combined

In-process control, hygienic design and isolator integration ensure that our solutions not only offer maximum versatility, but also highest product safety.

Barrier systems

We focus on each component to make sure it seamlessly interacts with others: safe interfaces between filling machines, isolators and subsequent equipment.

Service Agreements

Find out more about our Service Agreements here.

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Digital Solutions

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Parts

Find out more about Parts here.

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Maintenance

Find out more about Maintenance here.

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Technical Support

Find out more about Technical Support here.

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Modernizations

Find out more about Modernizations here.

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Training

Find out more about our Training here.

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Expert Services

Find out more about our Expert Services here.

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Portfolio overview

Ampoule brochure

Our solutions for processing ampoules

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Ampoule filling machines

Ampoule processing details & features

Solutions for complete ampoule lines

Opening station for closed ampoules