ZONESUN ZS-FAL180SY1 Automatic Prefilled Syringe Filling and Capping Production Line

ZONESUN ZS-FAL180SY1 Automatic Prefilled Syringe Filling and Capping Production Line

Description 

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, 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 optional Class 100 laminar flow hood for higher cleanliness requirements.

Parameter

• Machine Model: ZS-FAL180SY1
• Machine Voltage: 380V/220V, 50–60 Hz
• Machine Power: 6 kW
• Applicable Syringe Size: 0.5–50 mL
• Syringe Mold: Different syringe sizes require different molds
• Filling Range: 0.3–50 mL
• Filling Pump: Different filling volumes may require changing the filling pump
• Number of Filling Heads: 1
• Number of Capping Heads: 1
• Filling Accuracy: ≤ ±1%
• Production Capacity: 1,800–2,400 Syringes/Hour
• Compressed Air Requirement: 0.55–0.75 MPa, 20 L/s
• Machine Dimensions: About L3400 × W950 × H1800 mm (Excluding Laminar Flow Hood)
• Machine Weight: About 1100 kg

Key Features

• Automatic Syringe Feeding Station: Automatically sorts and transfers syringe components into the production line, reducing manual handling and maintaining consistent material supply.
• Siliconization & Assembly System: Japanese micro-atomization spray valves provide precise and splash-free siliconization while the synchronized assembly mechanism completes stopper installation.
• Top Filling Structure: Syringes are inverted before filling, allowing liquid to enter from the syringe tip to minimize residual air inside the barrel and improve filling consistency.
• Ceramic Pump Filling System: Ceramic volumetric pump provides accurate and stable dosing with filling accuracy of ≤±1% for reliable pharmaceutical production.
• SUS316L Vibratory Cap Feeder: Polished SUS316L stainless steel vibratory bowl automatically sorts and supplies caps while minimizing difficult-to-clean dead corners.
• Servo-Controlled Capping Station: Servo-controlled capping mechanism provides stable assembly quality and can be configured for different prefilled syringe cap structures.
• Automatic Reject Removal: Integrated reject removal function helps remove non-conforming products from the production process for improved quality control.

Benefits

• High Production Efficiency — Fully automated operation achieves 1,800–2,400 syringes/hour for continuous prefilled syringe production.
• Accurate Filling Performance — Ceramic pump dosing provides ≤±1% filling accuracy for consistent product volume.
• Reduced Residual Air — Inverted tip-side filling helps minimize residual air inside the syringe barrel and improves filling consistency.
• Precise Siliconization — Micro-atomization spray technology provides controlled and splash-free siliconization for smooth syringe performance.
• Hygienic Product Contact — SUS316L product-contact components and medical-grade silicone support demanding pharmaceutical and medical production requirements.
• Reduced Manual Handling — Integrated feeding, assembly, siliconization, filling, cap feeding, capping, and reject removal significantly reduce operator intervention.

Application

Ideal for automatic production of prefilled catheter flush syringes and other plastic prefilled syringe products requiring precise filling, component assembly, and automatic capping. Suitable for pharmaceutical and medical device production lines requiring filling accuracy of ≤±1%, reduced residual air, hygienic product-contact materials, and consistent automated production.

Automatic Feeding Station

Automatically sorts and transfers syringe components into the production line, reducing manual handling and improving production 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

The syringe is inverted before filling, allowing the product to be filled from the syringe tip to minimize residual air inside the barrel. Ceramic pump provides accurate volumetric filling.

Vibratory Cap Feeding System

Manufactured from polished SUS316L stainless steel, the vibratory bowl automatically sorts and supplies caps without creating difficult-to-clean dead corners.

Automatic Capping Station

Servo-controlled capping mechanisms ensure stable assembly quality and can be configured for different prefilled syringe cap structures.

Why Choose the ZONESUN ZS-FAL180SY1?

✅ 1,800–2,400 Syringes/Hour — Efficient Automated Production: Integrates syringe feeding, siliconization, assembly, filling, cap feeding, capping, and reject removal into one continuous process, reducing manual operation and improving production efficiency.

✅ Ceramic Pump Filling — ≤±1% Dosing Accuracy: The ceramic volumetric pump provides precise and repeatable liquid dosing for prefilled syringe production, supporting filling volumes from 0.3 to 50 mL.

✅ Inverted Tip Filling — Reduced Residual Air: Syringes are inverted before filling so the product enters from the syringe tip, helping minimize residual air inside the barrel and improve filling consistency.

✅ Micro-Atomization Siliconization — Precise & Splash-Free Coating: Japanese micro-atomization spray valves provide controlled siliconization while minimizing splashing, followed by synchronized stopper assembly.

✅ SUS316L Cap Feeding System — Hygienic Automatic Supply: The polished SUS316L vibratory bowl automatically sorts and supplies caps while reducing hard-to-clean dead corners for improved hygiene.

✅ Servo-Controlled Capping — Stable Assembly Quality: Servo-controlled capping provides consistent assembly performance and can be configured to accommodate different prefilled syringe cap structures.

✅ Optional Class 100 Laminar Flow Hood — Higher Cleanliness Capability: The production line can be equipped with an optional Class 100 laminar flow hood for applications requiring a higher-cleanliness operating environment.

Ideal Applications

Catheter Flush Syringes: Ideal for automatic production of prefilled catheter flush syringes requiring accurate liquid dosing, low residual air, and consistent cap assembly.

Plastic Prefilled Syringes: Suitable for various plastic prefilled syringe products within the supported 0.5–50 mL syringe size range.

Medical Device Production: Designed for medical device manufacturers requiring automated syringe feeding, siliconization, assembly, filling, and capping processes.

Pharmaceutical Filling: Suitable for applicable pharmaceutical liquid products requiring precise ceramic pump dosing and hygienic product-contact components.

High-Cleanliness Production: Optional Class 100 laminar flow hood supports production environments requiring enhanced cleanliness around the filling and capping process.

Automated Syringe Production Lines: Provides an integrated solution for manufacturers seeking to combine syringe component feeding, assembly, filling, capping, and reject removal into a continuous automated workflow.