ZONESUN ZS-DM1 Automatic Prefilled Syringe Denesting Machine

ZONESUN ZS-DM1 Automatic Syringe Denesting Machine for Prefilled Syringe Production Line

The ZONESUN ZS-DM1 is an automatic prefilled syringe denesting machine designed to remove syringes from nest tubs and transfer them individually to downstream filling and stoppering equipment. It supports common prefilled syringe formats including BD, BG, SCHOTT and SCF, with customized handling solutions available for different syringe specifications.

Built with a SUS304 stainless-steel frame, SUS316L product-contact components and medical-grade silicone parts, the machine is designed for pharmaceutical and clean production environments. PLC touchscreen control provides real-time operation monitoring, fault detection and alarm functions for stable production.

The ZS-DM1 can operate as a standalone denesting system or be integrated into a complete automatic prefilled syringe filling and stoppering line. An optional Grade A laminar flow hood is available according to production and cleanliness requirements.

Technical Parameters

• Machine Model: ZS-DM1
• Voltage: 380V/220V 50/60Hz
• Total Power: 0.8 KW
• Applicable Syringe Specifications: 0.5-10 ml (Different specifications of syringes need to replace the mold)
• Compressed Air: 0.55-0.75 Mpa, 15 L/S
• Machine Size (L*W*H): 22309001800 mm (Without laminar flow hood)
• Machine Weight: 400 KG

Key Features

• Automatic Syringe Denesting: Removes prefilled syringes from nest tubs for continuous downstream processing.
• Individual Syringe Transfer: Transfers syringes individually and consistently to downstream filling and stoppering equipment.
• Multiple Syringe Formats: Supports common BD, BG, SCHOTT and SCF formats with customized change parts available.
• PLC Touchscreen Control: Enables convenient operation, real-time monitoring, fault detection and alarm management.
• Clean Production Design: SUS304 frame with SUS316L and medical-grade silicone components in applicable contact areas.
• Optional Laminar Flow Protection: Grade A laminar flow hood can be configured according to production requirements.
• Flexible Line Integration: Suitable for standalone operation or integration into an automatic prefilled syringe production line.
  

Typical Prefilled Syringe Line Workflow

Nest Tub Feeding → Tub Opening → Syringe Denesting → Syringe Transfer → Liquid Filling → Stopper Insertion → Finished Syringe Collection

The ZS-DM1 performs the automatic syringe denesting and transfer stage within a prefilled syringe production line. Upstream and downstream equipment can be configured according to syringe format, filling process, required capacity and production environment.

Benefits

• Streamlined Production Flow — Automates syringe unloading to eliminate manual handling bottlenecks and boost line efficiency.
• High Hygienic Compliance — Medical-grade contact materials and cleanroom-ready design satisfy international pharmaceutical standards.
• Damage-Free Syringe Handling — Gentle mechanical transfer protects fragile glass and plastic syringe barrels from collision or scratches.
• Format Versatility — Quick adaptability across major syringe tub brands ensures maximum operational flexibility on the factory floor.
• User-Friendly Maintenance — Real-time monitoring and smart diagnostic alarms reduce downtime and simplify daily troubleshooting.

Applications

The ZS-DM1 is designed for automated handling of nested prefilled syringes used in:

• Pharmaceutical filling lines
• Prefilled syringe production
• Sterile filling applications
• Medical device production
• Laboratory and clean production environments

Syringe handling components and line configurations can be customized according to the required syringe format and production process.

Why Choose the ZONESUN ZS-DM1?

✅ Automatic Syringe Denesting System — Efficient Nest Tub Separation: Designed to automatically remove prefilled syringes from nest tubs and transfer them individually to downstream filling, stoppering, or assembly lines, reducing manual handling and improving production efficiency

✅ Wide Syringe Format Compatibility — Flexible Production Adaptation: Supports various syringe formats including BD, BG, SCHOTT, SCF, and other customized specifications, providing a versatile solution for different pharmaceutical packaging requirements

✅ Precise One-by-One Syringe Transfer — Reliable Downstream Feeding: Advanced denesting technology ensures accurate separation and smooth transfer of individual syringes, minimizing handling errors and supporting stable operation of automated pharmaceutical lines

✅ Pharmaceutical-Grade Material Construction — Hygienic & Durable Design: Built with a SUS304 stainless steel frame, while product-contact components use SUS316L stainless steel and medical-grade silicone to meet strict pharmaceutical hygiene and material requirements

✅ PLC Touchscreen Control — Intelligent Operation Management: Equipped with an advanced PLC system and touchscreen interface for real-time monitoring, parameter adjustment, and intuitive machine operation, reducing operator training requirements

✅ Fault Detection & Alarm System — Easy Maintenance: Integrated diagnostic functions automatically detect operating issues and provide alarms, helping operators quickly identify problems and reduce equipment downtime

✅ Modular Standalone or Inline Integration — Flexible Production Layout: Features a modular design that allows independent operation or seamless connection with syringe filling, stoppering, and other pharmaceutical processing equipment

✅ Optional Grade A Laminar Flow Hood — Enhanced Cleanliness Protection: Available with an optional Grade A laminar airflow system to provide a higher cleanliness environment and further reduce contamination risks for sterile syringe processing

Ideal Applications

Pharmaceutical Manufacturing: Ideal for prefilled syringe production lines requiring automated syringe transfer, precise handling, and compatibility with sterile pharmaceutical filling and stoppering processes

Medical Device Production: Suitable for disposable syringe and medical device manufacturers needing reliable denesting solutions for high-volume automated assembly and packaging operations

Biotechnology & Sterile Products: Applicable for handling sensitive sterile products where controlled environments, contamination reduction, and precise syringe positioning are essential

Healthcare Packaging Lines: Designed for integration with syringe filling, stoppering, inspection, and packaging systems to improve automation efficiency and maintain consistent product quality

Pharmaceutical Automation Systems: Provides a flexible feeding solution for modern sterile production facilities requiring modular equipment integration and reliable continuous operation