Generates and Distributes Ultra-Pure Water and Steam

Syntegon’s Pure Media Systems, featuring the Pharmatec MWFI System, revolutionize the generation and distribution of ultra-pure water and steam for pharmaceutical and biopharmaceutical industries. Designed with modularity and skidded drop-in installation, these systems employ advanced processes such as ultrafiltration and reverse osmosis to ensure high purity levels, effectively supporting applications in liquid formulations, tablets, capsules, and sterile solutions like saline and paracetamol. The systems facilitate continuous operation, integrating seamlessly with existing production lines through PLC automation, while maintaining superior energy efficiency with significant reductions in operational costs. Constructed with durable stainless steel, these systems are compliant with GMP standards, offering reliable sanitary performance. Maintenance is streamlined through easy-access designs, and optional ozone sanitation enhances microbial protection. Custom engineering support allows adaptation to specific process requirements, ensuring optimal performance across diverse pharmaceutical and biotechnology applications.

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Mixes and Granulates Pharmaceutical Powders

The high-shear mixer granulator from Syntegon, featuring the innovative Hüttlin Gentlewing impeller, is specifically designed for pharmaceutical and nutraceutical production lines. It excels in mixing and granulating powders into uniform granules, crucial for oral solid dosage forms like tablets and capsules. Its unique impeller design ensures superior mixing and reduced wall caking, enhancing yield and process reliability. You can achieve granulation of challenging products like high-potent APIs and effervescent tablets, with batch capacities ranging up to 1,800 liters. Automation is seamless with its PLC-controlled system, supporting remote operation and integration into existing lines.

Offering energy efficiency through optimized motor control, this equipment minimizes solvent use and pollution. Available in top or bottom drive configurations, it features a purged sealing system to prevent cross-contamination, and is constructed from corrosion-resistant materials suitable for GMP environments. Maintenance is straightforward with integrated CIP systems, ensuring rapid cleaning cycles. Customization options like variable impeller designs and containment upgrades are available to meet specific production needs.

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Processes and Coats Pharmaceutical Powders and Pellets

The Syntegon Fluid Bed Processor offers pharmaceutical and nutraceutical manufacturers an indispensable solution for drying, granulating, and coating operations. Utilizing the unique Hüttlin Diskjet air distribution system and bottom spray technology, it provides homogeneous mixing and faster drying, catering to tasks like producing paracetamol tablets and vitamin D capsules. With batch capacities ranging from bench-top R&D sizes up to 1,600 kg, it ensures high throughput and versatility across processes. The processor’s three-component nozzle system enhances spray rates and product yield, supporting integration into continuous production lines with ease. Automated features, such as dynamic filtering and cleaning-in-place (CIP) options, meet stringent GMP standards, aligning with energy-efficient practices that lower operational costs. Available in industrial-grade materials to ensure chemical compatibility, this equipment exemplifies precision, compliance, and adaptability.

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Enables Precise Dosing and Continuous Production

The Xelum Continuous Manufacturing Platform from Syntegon is a transformative solution for the pharmaceutical and nutraceutical industries, offering seamless integration of precise dosing and continuous production for oral solid dosage forms. By leveraging discrete mass dosing, the Xelum platform eliminates the need for traditional scale-up, ensuring high content uniformity even for APIs below 1%. This system is ideal for producing a variety of products such as antibiotic tablets and antiviral capsules, thanks to its robust fluid bed processors that handle granulation and drying in a single chamber, avoiding wet granulate transfer and enhancing reliability. With throughput capacities ranging from 10 to 100 kg/h, Xelum supports rapid production cycles and maintains exact standards in API concentration.

The platform is fully automated, featuring PLC-controlled operations with direct process parameter transfers from R&D to production, allowing for efficient pilot and clinical trials without the constraints of scaling up. It accommodates complex formulations with contained capabilities for OEB4 materials and integrated WIP systems. Xelum’s design prioritizes energy efficiency, reducing production costs while maintaining flexibility for both tablets and capsules. Engineered to meet stringent GMP and FDA standards, it offers a clean-in-place (CIP) system ensuring fast, contamination-free cleaning, perfect for high-potent API development. Customization support allows for tailored configurations to suit specific manufacturing requirements, making Xelum a cornerstone for forward-looking production strategies.

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Fills and Seals Capsules with Precision

The GKF 702 from Syntegon offers a versatile solution tailored for R&D labs and small batch production, capable of handling up to 42,000 capsules per hour. This capsule filling machine excels in precise dosing of both HPMC and gelatin capsules with a modular design that facilitates quick changeovers between different product types, including powders, granules, and liquids. Utilizing a slide-gate technology, it ensures minimal product loss and maximized yields. Integrated with automated systems for dosing and weighing, it optimizes productivity in pharmaceutical, nutraceutical, and health product manufacturing. The machine’s design supports seamless integration into production lines with minimal operational downtime. With robust material options and compliance with industry standards, the GKF 702 ensures reliability and efficiency in diverse processing environments.

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Fills and Seals Capsules with Precision

The GKF Capsylon Series from Syntegon is an automated solution for precise capsule filling and sealing, tailored for the nutraceutical and pharmaceutical sectors. With a modular design, these machines adapt to fill a range of capsule types, from powders to granules, effectively reducing product waste and improving yield. Capable of producing up to 360,000 capsules per hour, the series is ideal for high-volume operations, including vitamins, probiotics, and herbal supplements. Integration into existing production lines is seamless, thanks to its PLC control and user-friendly interface. The machines are energy-efficient, featuring slide-gate technology that minimizes dust and product loss. Built from robust materials, they are compliant with GMP standards, ensuring quality and safety. Maintenance is streamlined through easy-to-clean components and optional CIP systems, while Syntegon offers extensive customization and support to meet diverse production needs.

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Ensures Precise Capsule Weighing and Quality Control

The KKE series from Syntegon offers a range of capsule checkweighers designed for pharmaceutical and nutraceutical production lines, ensuring precise weight control and quality assurance. Utilizing patented gravimetric weighing technology, these checkweighers deliver 100% capsule weighing accuracy, making them essential for applications involving gelatin, vegetarian, and specialty capsules such as probiotic and Omega-3 variants. Models like the KKE 1700 and KKE 3800 cater to medium and large volume productions, with throughputs ranging from 103,200 to 232,200 capsules per hour. Integrated with automated feedback loops and ASB (Automated Troubleshooting) functions, these machines enhance process efficiency and reduce downtime. Constructed to meet OEB 4 and OEB 5 standards, they offer dust-tight and wet-clean options for stringent compliance. The series is engineered for seamless in-line integration with Syntegon’s GKF capsule filling machines and provides robust support for CIP, ensuring easy maintenance and cleaning. With configurable options and engineering support, the KKE series is designed to optimize your production line while maintaining industry compliance and product quality.

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Detects Particulate and Cosmetic Defects

The AIM 8000 series from Syntegon represents cutting-edge technology in automated visual inspection systems. These machines specialize in the detection of particulate and cosmetic defects in pharmaceutical products, such as ampoules, vials, syringes, and cartridges. Using high-resolution camera systems and AI-driven image analysis, the AIM 8000 series enhances inspection accuracy while minimizing false rejects.

With its modular design, the AIM 8000 series accommodates a variety of container sizes and formats, ranging from 1 ml to larger capacities, ensuring flexibility in handling different products like insulin vials, vaccines, and biologics in cartridges. The system offers a throughput of up to 600 containers per minute, integrating seamlessly into both continuous and batch production lines.

Designed for efficiency, these machines utilize intelligent pre-spinning functions to homogenize products and eliminate air bubbles, further optimizing the inspection process. The incorporation of PLC control facilitates seamless automation and integration with existing line setups, while maintaining energy efficiency with its optimized motor systems.

Constructed from high-grade stainless steel, the AIM 8000 series ensures durability and resistance to corrosion, meeting stringent GMP and FDA compliance standards essential for pharmaceutical applications. Additionally, it features a built-in re-inspection function and supports Container Closure Integrity (CCI) testing, solidifying its role as a critical component in maintaining product safety and quality.

Engineered for ease of use, the series supports quick changeovers and includes customizable features to meet specific production needs, backed by Syntegon’s engineering support for tailored solutions.

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Fills and Packages Nutraceutical Capsules and Granules

Syntegon’s Nutraceutical Granule and Capsule Filling System offers a comprehensive solution tailored for the needs of nutraceutical producers and pharmaceutical manufacturers. Designed to improve operational efficiency, this system precisely fills capsules and packages granules, ensuring accurate dosage and minimal waste. Integrating seamlessly into both batch and continuous operations, it supports various production scales. The system accommodates a wide array of applications from encapsulating omega-3 capsules and vitamin tablets to packaging protein powder sachets and probiotic gummies.

With automation at its core, the system is equipped with PLC controls for streamlined operations and offers remote monitoring for enhanced production oversight. The equipment is constructed with durable stainless steel options, ensuring compliance with GMP standards and reliability under extensive operational use. Maintenance is efficient with an integrated CIP system that allows thorough cleaning without manual intervention. Additionally, customization options are available to adapt filling and packaging capabilities to specific product requirements, providing engineering support to optimize your production line.

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Automates Product Handling and Packaging Processes

The Syntegon Robotic Pick and Place Platform (RPP) offers a game-changing solution for diverse industries seeking to advance their packaging operations. This modular platform excels in automating product handling and placement with precision and efficiency.

Using integrated delta robots, the RPP system provides seamless product loading into trays or cartons, capable of achieving up to 140 picks per minute per robot, optimizing high-speed environments. Its design supports applications across pharmaceuticals, bakery products, confectionery, dairy, and more, enhancing operations from ampoules to chocolate bars.

With its compact footprint, the RPP is PLC-controlled, supporting remote monitoring and smart interface integration for scalable capacity adjustments. Its construction in stainless steel offers superior hygienic operations and compliance with rigorous industry standards, including IP65 protection for wash-down scenarios. The platform’s vision-guided inspection technologies ensure tight quality control, identifying and removing any defective products in the process.

Syntegon’s RPP system includes quick-change end-of-arm tooling for format flexibility, supporting gentle and safe product handling while reducing contamination risks. It simplifies cleaning with its open-channel, self-draining design, paired with optional CIP systems. Custom configurations and engineering support are available to tailor the platform to your specific production demands, ensuring streamlined integration into existing production lines.

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