Marya Integrated Syringe Filling and Plunger Insertion Machine with Vision Inspection

• Customization: Available
• Automatic Grade: Fully Automatic
• Material Type: Liquid
• Model NO.: Piston Filling Machine
• Filling Valve Head: Multi-Head
• Feed Cylinder Structure: Multi-Room Feeding
• Dosing Device: Rotor
• Filling Principle: Pressure
• Packaging Container Lifting Structure: Customized
• Structure: Rotary
• Packaging: Syringe
• Packaging Material: Plastic
• Filling Accuracy: 99%
• Isolator: Optional
• Rejected System: Equipped
• Flow Sensor: Equipped
• CIP/SIP System: Optional
• Transport Package: Wooden Packing
• Specification: Standard/ Customized
• Trademark: Marya
• Origin: China
• Production Capacity: 50000pieces/Year

Product Description

Maya Integrated Syringe Filling and Plunger Insertion Machine with Vision Inspection

Product Description

     The syringe filling machine is specially designed for pre-filled syringes (PFS). Equipped with PLC touch-screen control, the machine enables easy parameter setting with fault alarm function. Modular structure facilitates format change-over and commissioning. It can work standalone or connect to complete aseptic production lines. It is suitable for mass production of pre-filled products in pharmaceutical, biotech and medical-aesthetic industries.

 

Application

This filling line is widely used in core fields such as pharmaceutical manufacturing and medical consumable production. It is particularly suitable for manufacturers of prefilled plastic syringes and disposable catheter flushers. The line can be employed for filling products that demand extremely high aseptic conditions, including clinical catheter flush solutions, vaccines, biological products, and aesthetic skin booster injections.

Features

1. Compliance & Traceability: Meets GMP Validation Requirements

• The machine is equipped with a PLC-based intelligent control system, enabling real-time monitoring and full traceability of all production parameters, including cleanliness, flushing pressure, and filling volume. It can automatically generate production reports, assisting enterprises in completing the full validation process of IQ (Installation Qualification), OQ (Operational Qualification), and PQ (Performance Qualification). This helps ensure successful compliance with pharmaceutical industry regulations and mitigates production compliance risks.
• The machine features a modular design with a compact structure, facilitating CIP (Clean-in-Place) and SIP (Sterilize-in-Place). It supports the production of various pharmaceutical liquids such as vaccines, biological products, and sterile flush solutions. The machine allows quick changeover between different models of syringes/catheters, meeting the requirements of pharmaceutical enterprises for large-scale, standardized aseptic production. We uphold the essential standards of aseptic compliance, improve production efficiency, reduce operational and maintenance costs, assist manufacturers in producing high-quality sterile medical consumables that meet industry standards, and strengthen their core market competitiveness.

 

2. Full-Process Aseptic Closed-Loop: Eliminates Secondary Contamination

• Aseptic Filling: The system adopts an isolated closed filling design, ensuring no exposure during liquid transfer. Equipped with a rotary ceramic pump and servo control system, the filling accuracy is controlled within ±1%. It is compatible with prefilled syringes of various volumes ranging from 0.1 to 20 mL, minimizing liquid waste and dosage deviation.
• Integrated Automatic Operation: The machine integrates filling, stoppering, and sealing into a fully automated process with no manual intervention. An online seal integrity detection system ensures leak detection accuracy ≤ 0.01 mL, and non-conforming products are automatically rejected, ensuring that every finished product meets aseptic standards.
• Flexible Adaptability: The modular design offers a compact structure, easy cleaning, maintenance, and upgrade. It supports rapid changeover between different sizes of catheters and multiple types of liquid (e.g., vaccines, insulin, sodium chloride flush solution). Parameters can be customized according to enterprise requirements, accommodating both large-scale batch production and small-batch custom orders.

 

3.  Intelligent Control

• Equipped with an intuitive human-machine interface (HMI), the system enables real-time monitoring of equipment operating status, aseptic environmental parameters, and filling accuracy. Parameters can be stored and retrieved, ensuring full production traceability, facilitating quality control and compliance audits, and reducing operational, maintenance, and training costs.

4.  Material Compliance: Meets Medical-Grade Biocompatibility Standards

• All components that come into contact with the liquid are made of medical-grade stainless steel 316L (in compliance with GB/T 1220-2019), with a surface roughness Ra ≤ 0.4 μm. The surfaces are electropolished to provide resistance to acids, alkalis, and chemical corrosion, with no leaching of harmful substances. The materials are validated to ISO 10993 for biocompatibility of medical devices, eliminating the risk of liquid contamination originating from the material itself, thereby meeting the strict material compliance requirements for the production of sterile medical consumables.

Product Parameters
 

Filling Range	0.1ml-20ml
Filling Mode	Customized (metal pump, peristaltic pump, ceramic pump)
Filling Accuracy	±1%
Silicone Oil Spraying Accuracy	0.5mg-2mg
Production Capacity	2000-30000 pcs/hour
Pass Rate	≥99.5%
Equipment Noise	≤70db
Power Supply and Power Rating	380V 50HZ

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