Prefillable Syringes

From needle insertion to the completely assembled product

Prefillable Syringes for Innovative Biopharmaceuticals.

Reasons for automation:

Plastic syringes are becoming more and more popular, because they can be produced adhering to tight tolerances and under clean room conditions.  The production line includes every single production step so that the product does not leave the production system until it is hermetically packaged.

Project Definition:

Inserting needles into an injection mold, each in size between 27 to 29 G (outside diameter between 0.360 and 0.286 mm) requires a separation process so that they can be taken up by the gripper. The needles are inserted into the injection mold and the syringe barrel is manufactured in a next step. In this process, the needle is surrounded completely by plastic. The gripper takes out the finished product after it has cooled off. After they have been taken out, the syringes are placed on a transfer shuttle. Then they run through various camera inspection stations. The flange is inspected in an initial inspection step, and the syringe barrel is inspected in a second step. At the end of the inspection process, the syringe and the tip of the syringe are tested to ensure they are not bent and free of interior barriers. Afterwards, each needle is "siliconized". A protective cap is placed on the syringe barrel. A camera checks to ensure it is fitted correctly. - Standing upright, with the flange showing upward, the syringes are set down into a nest in groups of 100 or 160 units.


  • Total cycle time 30 seconds
  • Designed for clean room category 7 (EN ISO 14644-1)
  • Separation and insertion of even the smallest size needles
  • 100% visual quality inspection
  • Assembly of protective caps