ZONESUN ZS-FAL180SY1 Automatic Prefilled Syringe Filling & Capping Production Line
The ZONESUN ZS-FAL180SY1 is an automatic prefilled syringe filling and capping production line designed for producing prefilled catheter flush syringes and other plastic prefilled syringe products. It automatically handles feeding, assembly, siliconization, filling, cap feeding, capping, and reject removal, achieving 1,800–2,400 syringes per hour. Syringes are inverted and filled from the tip side using ceramic pumps to minimize residual air and improve consistency. Product-contact parts are made of SUS316L stainless steel and medical-grade silicone, with an optional Class 100 laminar flow hood for higher cleanliness requirements.
Key Features
- Automatic Feeding Station – Automatically sorts and transfers syringe components into the production line, reducing manual handling and improving consistency.
- Siliconization & Assembly Station – Japanese micro-atomization spray valves deliver precise, splash-free siliconization, while the assembly mechanism completes stopper installation in a synchronized process.
- Top Filling Structure (Inverted Filling) – Syringes are inverted before filling so product is filled from the tip, minimizing residual air inside the barrel. Ceramic pumps provide accurate volumetric filling with ≤±1% accuracy.
- Vibratory Cap Feeding System – Polished SUS316L stainless steel vibratory bowl automatically sorts and supplies caps without hard-to-clean dead corners.
- Automatic Capping Station – Servo-controlled capping ensures stable assembly quality and supports different prefilled syringe cap structures.
Benefits
- High Efficiency – 1,800–2,400 syringes per hour with full automation from feeding to capping.
- Accurate Filling – Ceramic pumps deliver ≤±1% filling accuracy with minimal residual air.
- Aseptic Design – SUS316L contact parts and optional Class 100 laminar flow hood meet pharmaceutical GMP standards.
- Precise Siliconization – Splash-free micro-spray coating ensures smooth syringe plunger performance.
- Labor Saving – Integrated process from feeding to capping reduces manual operation and contamination risk.
Technical Specifications
| Model | ZS-FAL180SY1 |
|---|---|
| Voltage | 380V / 220V, 50–60 Hz |
| Power | 6 kW |
| Applicable Syringe Size | 0.5–50 mL (different sizes require different molds) |
| Filling Range | 0.3–50 mL (pump change may be required) |
| Filling Heads | 1 |
| Capping Heads | 1 |
| Filling Accuracy | ≤±1% |
| Production Capacity | 1,800–2,400 syringes/hour |
| Compressed Air | 0.55–0.75 MPa, 20 L/s |
| Machine Dimensions | ~3400 × 950 × 1800 mm (L × W × H, excl. laminar flow hood) |
| Machine Weight | ~1,100 kg |
Configuration Options
- With Laminar Flow Hood – Class 100 laminar flow hood for aseptic filling environments (recommended for pharmaceutical GMP lines)
- Without Laminar Flow Hood – Standard configuration for general medical device production
- Automatic Feeding System – Choose Liquid Feeder or Paste Feeder depending on product viscosity
Applications
Ideal for automatic production of the following prefilled syringe products:
- Prefilled catheter flush syringes (saline, heparin)
- Prefilled injection syringes for pharmaceutical use
- Plastic prefilled syringe products for medical devices
Suitable for pharmaceutical manufacturers and medical device companies requiring high accuracy, sterility, and consistent quality in prefilled syringe production.
Component Details
Automatic Feeding Station
Automatically sorts and transfers syringe barrels and components into the production line, reducing manual handling and ensuring consistent orientation for downstream processing.
Siliconization & Assembly Station
Japanese micro-atomization spray valves deliver precise, splash-free silicone coating inside the syringe barrel, while the synchronized assembly mechanism completes stopper installation.
Inverted Ceramic Pump Filling
Syringes are inverted for tip-side filling using ceramic pumps, minimizing residual air in the barrel and achieving ≤±1% volumetric filling accuracy for consistent product quality.
Vibratory Cap Feeding System
Polished SUS316L stainless steel vibratory bowl automatically sorts and continuously supplies caps to the capping station without dead corners that are difficult to clean.
Servo-Controlled Capping Station
Servo motor-controlled capping mechanism ensures stable, consistent cap assembly quality and accommodates different prefilled syringe cap structures with precise torque control.
Optional Class 100 Laminar Flow Hood
Optional Class 100 laminar flow hood creates a localized aseptic environment over the filling and capping zone, meeting pharmaceutical GMP requirements for sterile prefilled syringe production.
