Marya Cartridge Bottle Washing, Air Drying, Siliconization, Drying, Sterilization, and Capping Linkage Production Line
The performance and accuracy of Marya cartridge bottle filling and capping production line can be combined to meet the new GMP requirements, which can help you handle cartridge bottles under the best conditions. Our cartridge filling system reliably supports every step of your production cycle, from precise positioning under workstations to low particle capping using patented technology, from small-scale production of specialty drugs to large-scale distribution of products.
Production Introduction:
This cartridge filling line is composed of four equipment: an ultrasonic bottle washing machine, an air-drying silicone oil injection integrated machine, a sterilization dryer, and a cartridge stoppering filling capping machine. It can complete complex functions such as spraying water, ultrasonic cleaning, air & water flushing of the inner and outer walls of cartridge bottles, air drying, silicone oil spraying, preheating, drying, and sterilization, heat source removing, cooling, stoppering, filling, capping, etc., achieving automation of the entire process. Each machine can be used alone or work in a linkage line, mainly used for the production of cartridge injections under sterile conditions in the pharmaceutical industry.
Applicable Industries:
Marya cartridge filling line is mainly used in the fields of biomedicine and cosmetics, and is suitable for the filling and production of vaccines, insulin, antibiotics, interferon, anesthetics and sedatives, and beauty products such as Hyaluronic acid. The finished product can also be used in medical industries such as ophthalmology, dentistry, otology, orthopedics, gynecology and other medical industries.
Performance Feature:
1. Wide range of applicable specifications, large production capacity, and high filling accuracy:
| Applicable specifications |
1.5-3ml |
| Production capacity |
~8400 bottles/ hour |
| Number of bottom stoppering head |
4 |
| Number of filling heads |
8(filling at twice) |
| Filling accuracy |
up to ±1% |
| Stoppering qualified rate |
≥99% |
| Capping qualified rate |
≥99% |
2. Mature technology, adopting industry-leading high-end technology, stable performance, and cost savings:
(1)This line is a full servo motor system controlled model, and the parameters that need to be adjusted can be adjusted on the touch screen;
(2)Adopting an advanced electrical control system, the operating speed can be adjusted steplessly, with complete interlocking function, and the operating parameters are displayed centrally on the display screen;
(3)High degree of automation, capable of automatic data collection, reliable monitoring and recording of key process data on the production line;
(4)The parts in contact with the drug solution are made of 316L stainless steel or silicone, and the other surfaces are made of 304 stainless steel or POM (PE);
(5)Equipped with full line linkage function, front and rear equipment linkage control;
(6)Adopting high-precision color touch screen operation monitoring, PLC automatic control, automatic protection, host frequency conversion speed regulation and other control technologies for fully automatic control and monitoring of the production process;
3. Multiple functions are available, customized according to your needs:
(1)The servo motor can be configured to control the filling pump for filling, with high filling accuracy and convenient adjustment;
(2)Configurable online cleaning and sterilization CIP/SIP system;
(3)The equipment has a compact structure with a glass door protection cover, and can be equipped with an Open-RABS/Close-RABS isolation protection system and 100-level air purification laminar flow system;
(4)Can be equipped with a vacuum filling system for filling high viscosity products;
(5)According to whether the customer's product is toxic or active, the fully enclosed sterile isolation system can be configured;
(6)Configurable glove testing system: Thin elastic gloves typically form the only barrier separating the machine and operator. Therefore, they are crucial for many different barrier systems and therefore require regular and repeated testing;
(7)Configurable pallet loading ensures the process of transporting cartridges is gentle, safe, and fast;
The production process steps of the Marya cartridge filling production line:
1. Cleaning:
Thorough cleaning of the inside and outside of the cartridge before filling and sealing is a crucial process step to remove residues and other pollutants from the inside and outside of the container. This step can prevent potential residual harmful substances from affecting the safety of the product and users. The Marya ultrasonic cleaning system has a wide range of applications, is an efficient, hygienic, and cost saving design solution that can assist customers in cleaning various types and specifications of containers, with simple operation and quick run.
Significant advantages:
Three water and three gas cleaning: ultrasonic cleaning, circulating water, injection water, compressed air injection etc. clean the inside and outside of the bottle multiple times to prevent cross contamination;
Cost saving: Independent recycling and filtration of circulating water, saving energy consumption costs;
Ergonomic design: Easy to adjust specifications and quick format changes improve operational flexibility;
2. Sterilization tunnel oven:
Whether you are filling liquid drugs into ampoules, vial bottles, injection and infusion bottles, cartridges, or syringes, the reliable pre-treatment of the container greatly contributes to product safety. Marya can provide various types of solutions, efficiently and continuously processing all different containers through preheating, high-temperature sterilization, and cooling stages to meet customer needs.
Significant advantages:
Fully automated: automatic bottle feeding,bottle delivering without the need for operator intervention, improving operational efficiency;
Tunnel type hot air circulation: The heat source is evenly distributed, and the effect of removing heat is good;
Customized: The drying sterilization and heat removal system can be customized according to customer needs;
3. Filling and sealing:
Marya's filling system for pre-sterilization and bulk containers has both flexibility and accuracy: various filling technologies, including valve piston and peristaltic pump, material flow and time pressure filling, ensure that you can fill your products in a highly customized way. The tool format does not need to be changed. The filling station with a variable number of filling heads can improve the flexibility of the filling process. The subsequent sealing also comes in various ways, providing you with various methods, such as gas combustion or inserting vacuum plugs to seal the container. The Process Control (IPC) system further improves the filling quality by continuously checking the filling capacity and rubber plug position.
Significant advantages:
High accuracy filling process: use a positioning dial to deliver bottles (driven by a servo motor), and deliver 4 bottles at a time, ensuring accurate filling positioning;
Adopting ceramic rotary valve pumps (8 sets) for 2-time filling, saving costs;
Can provide a combination of filling and capping machine;
Fully integrated barrier system (RABS, enclosed RABS, or isolator);
4. Barrier system:
Aseptic filling is related to product safety and requires the separation of operators and drug ingredients. Isolator technology helps establish this critical barrier. With years of experience in barrier system design and manufacturing, Marya has established a comprehensive product portfolio, including open RABS, closed RABS, closed systems, and isolation systems. We focus on the connection design of each functional section to ensure seamless interaction with other parts.
Significant advantages:
Safe filling of sterile and potent products;
In-depth research on RABS, isolators, and related barrier technologies;
Single source isolator, biological purification, and air treatment;
5. Freeze-drying process:
For many years, freeze-drying has been successfully used to extend the shelf life of liquid drugs. The Marya freeze-drying process can be applied to the drying production of raw materials such as raw materials, traditional Chinese medicine slices, biological products, vaccines, blood products, active substances, antibiotic drugs, food, fruits, chemicals, pharmaceutical intermediates, etc., and to develop exclusive solutions for containers of different specifications for different products; The Marya freeze dryer allows products to be stored and transported for a long time after vacuum freeze-drying, maximizing the original activity of the product. Meanwhile, the Marya freeze dryer machine can be integrated into a complete set of washing, filling, and sealing machine systems, greatly saving costs and space.
Significant advantages:
Fully automated, reducing the tedious operation of the drying process;
Silicone oil freezing medium, error ≤ 1 ºC, uniform drying effect;
Our freeze dryer has a wide range of applications and can handle containers of different sizes and specifications;
At the same time, Marya can also provide you with ready-to-use RTU aseptic filling machines suitable for prefilled needles, vial bottles, and cartridge bottles.
As a leading supplier of filling and sealing solutions for nested syringes, vial bottles, and cartridge bottles, Marya has always been at the forefront of pharmaceutical machinery manufacturing. We use modular and space saving designs to help simplify the drug production process, reduce waste, and save costs.
Unlike the cartridge filling production line, the nested RTU container is brought to the filling machine in the clean room in the form of a single or double bag, and unpacked in half or full process. There are two main methods for transferring nest boxes to sterile areas. The first option is to use an electron beam or H2O2 for external purification. Another option is non-contact transmission (NTT).
The Marya filling device can be combined with fully automatic, semi-automatic, and manual operating devices with the latest features to meet dynamic market demands.
Ready-to-use applications reduce reliance on bulk procurement and significantly reduce floor space. Marya provides a combination system for nested packaging with excellent results, allowing the system to truly flexibly use multiple format types on the same model.
The automatic series of Marya aseptic RTU nested filling machines includes automatic bag removal, automatic removal of tyvec, automatic removal of sealing paper, and the use of vacuum for filling and stoppering operations, which can prevent any microbial contamination.
High flexibility, short conversion time, and excellent quality ensure the performance of our products, allowing our speciality to achieve your success.
Marya SO GMP Standard Cosmetic Glass Veterinary Tube Ampoule Filling Production Line
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