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Russia - РусскийAutomation Case Study: Automatic Pre-Filled Syringe Filling and Stoppering Solution
Customer Profile
A leading Indian manufacturer of pharmaceutical packaging machinery, established in 1996, specializing in injectable and prefilled syringe solutions, offering advanced combo filling and stoppering machines for syringes, vials, and cartridges, along with dual-chamber syringe fillers, plunger rod insertion units, and labelling systems. The company operates from a modern 20,000 sq. ft. facility with CNC machining, R&D, and validation capabilities. It delivers cGMP-compliant, high-precision, and cost-effective solutions for syringes, vials, and cartridges, and is recognised as a pioneer in the prefilled syringe filling and stoppering segment, catering to the needs of the growing pharmaceutical and biotech industry.
The Challenge
R&D labs and early-stage drug development teams require sterile, precise, and flexible small-batch filling systems. Key issues include manual errors, contamination risks, inconsistent micro-volume dosing, limited multi-format support, and difficulty scaling from trials to pilot production. Traditional systems are costly, bulky, and unsuitable for quick changeovers and GMP-compliant R&D environments.
The Solution
A compact combo prefilling and stoppering machine was developed using Inovance automation technologies:
- AM521-0808TN Motion CPU for synchronised, precise multi-axis control
- IT7100E HMI for simple operation, recipe management, and fast changeovers
- SV660N Servo Drives + MS1 Servo Motors for accurate, smooth filling and stoppering
The system handles 0.5 ml–2.2 ml syringe and cartridge volumes and supports multiple modes: Manual, Homing, Individual Auto Cycles, Full Auto, Single-Cycle, and Continuous Cycle. Additional features include alarm history, multi-level passwords, and HMI access control.
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Benefits
The solution delivers high filling accuracy and repeatability while significantly reducing contamination risks through automated operation. Its ability to support quick format changeovers for syringes, vials, and cartridges makes it ideal for dynamic R&D environments. The compact, GMP-ready design fits seamlessly into laboratory spaces, and its modular architecture enables easy scalability from small trial batches to pilot production, ensuring smooth progression through development stages.
Key Benefits
- Precise dosing through advanced motion control
- Improved sterility and reduced operator dependency
- Multi-format capability
- Faster development cycles
- Secure and controlled machine access
- Cost-effective, compliant solution
Conclusion
By integrating Inovance’s motion, servo, and HMI technologies, the combo prefilling and stoppering solution delivers a reliable, precise, and GMP-compliant platform for R&D and small-batch pharmaceutical applications. It enhances accuracy, sterility, and scalability—accelerating progress from development to commercialisation.