Marchesini Group Syringe Lines

Marchesini Group are world leaders in automatic machines for producing disposable syringes. They are the only company in the world capable of designing and manufacturing all the machines in a complete syringe line, from filling to palletising Marchesini Group syringe lines are the result of integration between various companies within the group. These include: Corima (specialised in filling, stoppering and assembly), Farcon (thermo-forming), Marchesini (cartoning, wrapping and palletising) Neri (labelling) and Multipack (stretch banding).

Syringe Filling

Marchesini Group not only produces all machines, it also offers a complete range of  accessories required for handling and assembling the syringes. This includes both conventional and new components such as Backstop and Safety Devices included in new international standards for the protection of operators in the health sector.

How is a conventional filling and packaging line structured?

Normally the empty syringes arrive to the packaging department placed vertically in nests which are contained within plastic tubs. These are wrapped in protective bags protecting their sterility during transport and storage. The first operation to be carried out is to remove the tub from its protective bag while preserving its sterility. Multipack have designed a unit called Alinext to automate this operation. A cutter removes the external bag, the tub with the syringes is then conveyed to the sterile chamber containing a controlled flow of air 99.97% purified. Under this laminar air flow the protective tyvex membrane is then removed either manually or automatically.

At this point a (Corima FSP Series) syringe filling machine fills the syringes in a controlled sanitised environment and applies a rubber stopper. Using the latest technology, the FSP is equipped with an innovative robotic system which is extremely flexible and capable of handling syringes of various sizes. The system is entirely controlled by Brushless motors guaranteeing maximum precision of dosage. It is also designed for the installation of all conventional protective laminar air flow systems or newer innovative barrier systems to limit access (RABs) to the process area whether open or closed.

Once these two operations have been completed, the syringes, filled and sealed with a rubber stopper are returned to their nest inside the tub to be taken to the next step in the secondary packaging process. Once filling and stoppering have been completed, the line secondary packaging requires the installation of a Denester, (Corima MP Series). This automatically picks up the filled syringes from the nests and feeds them into an inspection machine or a plunger insertion-labelling machine (Corima AEC Series).

The insertion of the plunger into the syringe, like the operations of pickup and moving the syringes, is precise and safe and designed to avoid any form of damage to the syringes, including aesthetic ones.  Equipped with a complete series of safety checks the AEC is available in different set-ups according to the production required and has been integrated with different types of printing and vision systems available on the market.

Syringe Assembly Machines

Downstream the plunger insertion-labelling machine, a syringe assembly machine with back-stop (Corima SMB Series) or a syringe assembly machine with safety device may be installed (Corima APS Series). The Safety Devices have been developed to avoid all possible contacts with the needle. They are normally activated automatically, isolating the needle inside them after injection. These devices are becoming more and more popular, being part of the safety standard protocol in an increasing number of countries. Both SMB and APS machines are designed and set up to be connected in line with other machines. They are reliable, versatile and capable of handling back-stop and safety devices of various sizes and form available on the market today.

As an alternative to standard machines, the Marchesini Group presents the top of the range  of Corima production, the APS Combi. This is the first machine in the world designed and produced to assemble syringes with the plunger, label the syringes with plunger already inserted and assemble the Safety Devices. Compact and extremely reliable, the APS Combi has already obtained great appreciation from the leading companies of the pharma sector. Available in a variety of different maximum speeds, the APS Combi carries out all operations automatically and has a variety of solutions making it easy to be integrated with downstream machines.

Once the syringes have been filled, labelled and assembled they are taken to the Farcon thermo-forming machine. The syringes are conveyed from Corima to Farcon through a system of connections and direct feed which includes the opportunity to store the syringes in an intermediate Buffer, also in F.I.F.O. (First In First Out) mode, as well as standard connecting conveyors.  Due to the various different ways of setting up a line, customised transport systems can be offered. For example the use of special shuttles in which the syringes are placed along with secondary components such as supplementary needles.

Farcon packages the syringes into thermo-formed containers using balcony style machines manufactured in compliance with the highest safety standards of the sector.

Farcon’s latest development is the FB320 thermo-forming machine, completely mechanical and controlled by brushless motors.

The syringes, sealed and protected by their thermo-formed container, are now taken to the final packaging. After the FB the most modern transport system is the Robocombi (Marchesini). This robotic feeding system picks up the containers from the outfeed conveyor of the FB and deposits them into the buckets of the cartoning machine with one walking-beam style movement.
Carrying out 400 pickups a minute the Robocombi guarantees high speeds but also great flexibility.

Trays with lids (whether made out of PVC or paper) are picked up by the top side by suction cups. However, open trays without lid are picked up by side grippers. Another important feature is the possibility to rotate the trays 90 degrees either flat or on edge, before placing them within the cartoner bucket chain. The ability to handle the trays in an extremely reduced space and with safe effective pickup, is one of the strong plus of the system. Besides stacking the required number of trays into the cartoner buckets, the Robocombi can also place them within dedicated, movable storing devices used for product buffering and / or off-line checks.

Disposable Syringe Lines

The cartoner can be chosen, among the many different available models, according to the presentation characteristics: number of containers to stack, their dimensions, other components to be inserted into the carton such as leaflets, booklets, etc.. and the production speed required.

Marchesini offers a wide range of labelling machines produced by their partner Neri for both product identification and protection. The labeler can apply not only vignette labels onto the carton but also Tamper Evident labels on the side flaps. The BL Neri range  of labelling machines is balcony style manufactured and is an example of technological high level and versatility. Once the product has been identified and the packaging securely sealed, we can proceed to the next step.

Cartons may be wrapped in bundles with heat sealed film (MF Series ), or in shrink wrap bundles (Multipack) however for disposable syringe lines packing into cases is more popular. Totally controlled by brushless motors and manufactured balcony style the MC series of case packers and palletisers complete the line. They can be provided as separate machines (MC820 and MP830) or in a single block (MCP840) guaranteeing a compact and efficient end of line, running at a speed of 10/15 cartons a minute.

Because of its capabilites of product handling and wide machine range Marchesini Group has no rivals at all. They guarantee automatic connection between all machines in the line, all electric and pneumatic components are standardised with a uniformity of design and supervision of production cycle. All the above at speeds varying from 2.000 to 24.000 pieces/hour.