Robotic System of Syringe-Filling Machine

I bet you have seen ready-to-use (RTU) vaccines somewhere. They have undergone an aseptic transfer method that uses a syringe-filling machine having a robotic system.

What Is a Robotic System of Syringe-Filling Machine

We can describe this as a technologically advanced system that can pre-fill a syringe. Such syringes normally have to reach the end-user as ready-to-use (RTU) products.

This fully automated system is a streamlined combination of complex advanced software technology and robotics. They work together with vision systems to offer you a seamless and precise procedure of filling and sealing your syringes.

Robotic Syringe Filling Machine
Robotic Syringe Filling Machine

Features of Robotic System Of Syringe-Filling Machine

  • You can customize the filling system to suit your application requirements
  • The frame is made of stainless steel with the exterior made of plastic material
  • Any motion in the system is facilitated by a servo drive
  • Controlled by Programmable Logic Controller (PLC) with a Human Machine Interface (HMI) for monitoring and operation
  • The system is fully automated save for feeding the empty pre-fill syringes

How a Robotic System of Syringe-Filling Machine Works

To get a clear understanding of its operation, we need to look at the different modules that the syringe passes through.

This system contains several operating modules with the significant ones being the filling, stopper placement, and sealing modules.

For the process to begin, you have to key in the process parameters based on the specifications of the syringe and the volume of medication. This is keyed in on the HMI that relays it to the PLC which controls the entire operation of this system.

We can start from the filling module where the empty syringes are picked by the robotic arm that arranges them in a filling station. The product medication is then placed inside the syringes in precise and pre-set amounts based on the dosage.

The next process module is the stopper placement module that containers the stoppers for the syringes. The filled syringes are delivered here where another robotic arm picks and places stoppers on them.

The pre-fill syringes with stoppers are then moved to the final robotic processing which is the closing module. This is the section where caps are placed on the filled syringes and seals are placed to prevent post-process contamination.

Robotic Syringe Filling Machine Working system overview
Robotic Syringe Filling Machine Working System Overview

The complete syringes have to undergo an inspection and rejection procedure. A robot integrated with sensitive cameras inspects them and removes all the defective ones.

You have to note that this process is fully automated with minimal human interaction with the product. This is t extremely reduces the rate of contamination and ensures product integrity.

Benefits of Robotic System Of Syringe-Filling Machine

With such advanced technologies, you are bound to experience the best in what this robotic system can offer. Let us have a look at the benefits you can get from the robotic system of the syringe-filling machine:

Lower Risk Of Contamination

This system reduces the physical contact between the syringe product and humans by limiting any form of intervention. The area of operation is normally enclosed and always sterilized.

This means that the contamination integrity of your syringes is guaranteed during the filling and sealing process.

High Precision

The robotic arm in the system has a very high precision. This means that your syringes have a consistent volume unlike if you would have filled them manually.

You will find this aspect very crucial, especially in instances where you are filling syringes with very sensitive medicine. The precise amount ensures that there is an exact dosage for each syringe that you fill.

Increased Productivity

The fact that this filling system can operate continuously for a long means that your output is increased and the efficiency improved. The number of syringes you can process is very much better than if you would have done it manually or using conventional machines.

If you’re running a pharmaceutical firm that requires very high volumes of production, then the robotic system is the right filling machine.


The flexibility of the robotic system allows you to change its operating parameters. This means that you can program it to fill different types of syringes of various shapes and sizes.

This is a major advantage especially if you’re producing different types of syringe medications in your venture. It also allows you to alter the dosages and offer them based on a patient’s medical requirements.

Speed And Efficiency

The fact that you have automated your syringe-filling process means that you can fill very many of them per hour. The availability of precision features such as peristaltic pumps ensures that losses are reduced since the volumes are to the set value.

Such speeds ensure that you can produce your high-value syringes in bulk and at a very short time. The lack of product loss further enhances the efficiency of your system and reduces losses.

Quality Assurance

You have a robot arm operating with very high precision in an automated system that is efficiently calibrated. The result for you is nothing but a quality syringe devoid of human error problems or contamination.

Besides this, your syringe product has no cross-contamination from the machine since everything is single-use. The process area is also isolated from any external environmental factors and is therefore safe.

Syringe Filling System
Syringe Filling System

Components of Robotic System Of Syringe-Filling Machine

Some of the main components of these filling machines include:

PLC Module

The programable logic controller is responsible for coordinating and executing all the operations of your syringe filler. It receives feedback from linked sensors and actuators and initiates motions through servo-drives.

It is also the component solely responsible for monitoring the status of your filler. It can run diagnostics and take appropriate operational measures to avert problems or correct errors.


This is the display panel that you will normally find as an LCD screen. You can input the process parameters here as well as monitor the overall operations of your syringe-filler.

Servo System

Powered by servo motors, this system is responsible for all the motion that takes place inside your syringe filler. It receives prompts and commands for the PLC and other controllers based on the process parameters.

Robotic Arms

In modern syringe-filler machines, you will find a six-axis robotic arm that has various functions in the filling process. Such processes include opening the tubs, filling the syringes, and sealing them.

Other additional tasks include rejecting substandard syringes. They are very dynamic and can handle all the processes in an extremely gentle way.

Technology Used In Robotic System of Syringe-Filling Machine

With the advancement in technology, the robotic system of syringe-filling has proven very resourceful. A lot goes in ensuring that the automation is top-notch and serves you to the fullest.

We can dive into some of the technological bits that give the place the robotic system a notch above the rest:

  • You have a robot that has an end-of-arm tool (EOAT). It uses this to transfer pre-fill syringes to the filling station right from the conveyor
  • There is a volumetric pump that is powered using a servo drive. This is what is responsible for filling the syringes with the medication product
  • There is a precision force sensor in the placement module. They detect the amount of pressure when placing the caps or the amount of torque if the syringe is screw-type
  • The robotic arms that pick syringes can locate them using an infrared vision system. This IR camera is integrated into the robotic arm
  • A programable logic controller (PLC) receives signals from other sensors and controllers to know what action to take. They coordinate the actions of your syringe filler and ensure that they are in tandem.
  • A human-machine interface (HMI) shows you the status of your machine. You can also input and set the desired parameters of your machine on this HMI
  • Various sensors are directly linked to the PLC. They are responsible for relaying the status of various components within your filler.


You should note that the various features you will find in a robotic system of syringe-filling machine vary across manufacturers. However, with the correct system requirements and proper maintenance, you will achieve the same from any of them.

If you are looking to increase your productivity in syringe-filling without getting multiple machines, then this is your sure bet. They have the highest precision while efficiently producing quality filled syringes with negligible contamination.

More Resources:

What is Aseptic Filling – Source: LOM

Packing Machine – Source: LOM

Packaging Systems for Injectable Products – Source: MYCO SCIENCE

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