Reduce drying time and improve uniformity with controlled fluidization

The Gansons Fluidised Bed Dryer is designed to dry powders and granules by suspending particles in a controlled stream of heated air, ensuring uniform contact between air and material. This fluidization enables consistent moisture removal across the entire batch while maintaining product integrity.

The system features a proprietary Cyklon air distribution design that generates a controlled swirl-flow pattern inside the process chamber. This eliminates dead zones and prevents material stagnation, significantly improving drying efficiency while reducing particle attrition and product loss.

The airflow system allows precise control over drying parameters, supported by push-pull fan configuration for stable and reproducible process conditions. This results in shorter drying times and consistent batch outcomes, even for sensitive or high-value materials.

The equipment is designed for pharmaceutical production environments, with cGMP-compliant construction, wash-in-place systems, and options for high-containment processing. Automation systems support recipe control, data integrity, and integration into regulated production workflows.

The system is scalable from development to production, with capacities ranging from approximately 10 L to 1,500 L.

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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 Sterilizes Liquid Parenteral Pharmaceuticals

The SVP Essential and LVP systems from Syntegon provide modular solutions tailored for liquid pharmaceutical manufacturing. Designed for flexibility, these systems handle mixing, homogenizing, and filling of both small and large volume parenterals. With capacities ranging from 13 to 20,000 liters, they integrate seamlessly into production lines through automation, enabling efficient batch and continuous operations. These systems feature robust CIP/SIP capabilities, ensuring rapid, contamination-free cleaning. Constructed with stainless steel, they comply with GMP and FDA standards, making them ideal for antibiotics, infusion solutions, and cell culture media production. The prefabricated cleanroom design reduces installation time and guarantees a minimal footprint, adapting to various production requirements. With over 70 pre-tested modules and ISA-88 structured automation, Syntegon’s solutions ensure process precision and operational control.

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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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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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Fills and Seals Vials for Liquid Pharmaceuticals

The FLC 3000 from Syntegon is designed to efficiently fill and seal vials in liquid pharmaceutical production lines, particularly for high-demand products like Covid-19 vaccines and monoclonal antibodies. Its compact GMP-compliant design supports a wide filling range of 0.2 to 500 milliliters and achieves throughput of up to 600 vials per minute, reducing changeover times with only three format part sets required. The machine’s peristaltic pump technology ensures precise dosing while maintaining sterility, and it integrates seamlessly into production environments with options for full in-process control. A clean and hygienic design facilitates easy maintenance and operator safety, meeting stringent GMP and FDA requirements. The FLC 3000 can be customized with additional filling technologies and systems as needed, providing robust support for both batch and continuous operations.

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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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