1. Manual De-bagging and Preparation

• • The operator manually removes the outer bag, Tyvek paper, and inlay sheet from the sterile syringe nested tub under the Extended Laminar Air Flow (LAF) unit.

2. Loading of Syringe Nested Tub

• • The prepared syringe nested tub is manually placed on the filling table.

3. Positioning at Filling Station

• • The filling table carrying the syringe nest is moved to the filling station.
  • The filling table is designed with synchronized X and Y axis servo movements for precise alignment with the filling needles.

4. Automatic Filling Volume Adjustment

• • The filling volume for each filling head/pump is automatically adjusted through servo-controlled dosing systems.
  • Fill volume parameters can be set and modified through the PLC-HMI interface.

5. Nitrogen Purging

• • Before filling, nitrogen purging is carried out using concentric filling needles.
  • An automatic control valve regulates nitrogen flow before, during, and after filling as per process requirements.

6. Product Filling Operation

• • The filling needles descend into the syringes.
  • Product is filled accurately into each syringe through servo-controlled filling pumps.
  • Needle movement is synchronized with the nest holding table to ensure precise and splash-free filling.

7. Completion of Filling

• • After completion of the filling cycle, the syringe nested tub is removed from the filling station.

8. Transfer to Vacuum Stoppering Station

• • The filled syringe nested tub is manually transferred and placed inside the vacuum chamber tray.

9. Placement of Rubber Stopper Nest

• • A rubber stopper nest is manually positioned over the filled syringes within the vacuum chamber.

10. Vacuum Stoppering Process

• • Vacuum is generated inside the chamber.
  • Stopper pins push the rubber stoppers into the syringe barrels.
  • The vacuum-assisted stoppering process minimizes air entrapment and ensures bubble-free stoppering.

11. Completion of Stoppering

• • After all stoppers are properly inserted, the vacuum cycle is completed and the chamber is vented.

12. Unloading

• • The stoppered syringe nested tub is removed from the vacuum chamber.

13. Transfer to Next Process

• • The filled and stoppered syringe nested tub is transferred to the subsequent manufacturing or packaging operation.