Skip to content
    back
    1080x1080_HeaderPictureFilling

    Pharmaceutical filling machines

    Protect product yield as aseptic requirements increase across liquid pharmaceutical manufacturing.

    Connect with our experts Downloads

    Keep aseptic filling stable as product demands shift

    Annex 1 requirements, diverse liquid formulations and yield targets are increasing expectations for pharmaceutical filling machines.

    As your strategic lifecycle partner Syntegon helps address these challenges with tailored filling technologies, automated control and yield-focused functions.

    Our pharmaceutical filling lines, your benefits

    How to automate filter testing before production?

    Run PUPSIT with less operator intervention.

    How to match filling technology to your product?

    Select the right filling setup for each application.

    How to maximize yield with high-value pharmaceuticals?

    Reduce waste, rejects and underfills.
    1000x667_PeristalticPump

    Peristaltic pump

    This pump handles shear-sensitive products particularly gently while protecting the product throughout the filling process. Because the product only comes into contact with the hose, the risk of cross-contamination is minimized. Clip connectors and the fact that no format parts are required beyond the hoses can significantly speed up changeovers significantly and reduce operator intervention, including in isolator environment. This pump type is also ideal for use with for single-use fluid path systems, which can further support Annex 1 compliant processes and reduce cleaning validation efforts.

    1000x667_RVP

    Rotary valve piston pump

    This highly flexible pump fills aqueous and highly viscous products precisely and drip-free using a volumetric operating principle. Designed for Annex 1 compliant cleaning and sterilization, this stainless-steel pump version supports reliable, high-quality filling performance. A ceramic version is also available for hot or abrasive products, extending the application range across different formulations. Optional Smart Pump RFID technology further improves repeatability of fill levels and simplifies predictive maintenance, helping reduce downtime and increase overall line efficiency.

    1000x667_TPF-2

    Time-pressure filling

    This system is designed for high product yield in high-performance applications and delivers consistently precise filling results. An intelligent algorithm and active suck-back technology help ensure precise, drip-free filling, reduce product loss and support fast format changes, minimizing downtime during product changeovers. With a minimum of moving parts, the closed system is also easy to access and clean despite its compact design, making it a strong solution for demanding pharmaceutical environments.

    1000x667_PumpTechnologies

    Sensor-Fill

    This sensor-based solution was developed specifically for the second full-fill step for cartridges, where precision is critical. It helps prevent overfilling and reduces product loss as well as contamination of cartridges, machines, and carriers. By minimizing the risk of residual air bubbles, it can significantly lowers reject rates and improves overall line efficiency. Sensor-Fill integrates seamlessly and is well suited for use in combination with our time-pressure filling system, making it a smart addition to existing filling lines.

    1000x667_RMP

    Rolling diaphragm pump

    This Syntegon-developed technology uniquely combines volumetric dosing precision with especially gentle product handling, moving liquid smoothly without shear-inducing surfaces. It is particularly well suited for biologics, proteins, and other shear-sensitive active ingredients commonly found in biopharmaceuticals, where maintaining product integrity throughout the filling process is essential. The fully closed system design supports both CIP/SIP and single-use versions, offering maximum flexibility to meet different production and compliance requirements.

    1000x667_MDM

    Mass flow filling

    This solution is designed for special applications such as x-ray products, highly potent cytostatics, or crystallizing formulations that require a particularly precise and reliable filling process. It also supports both hot and cold filling are also no problem for this system, extending its range of use further. Each filling section empties fully and features a dedicated Coriolis-based mass flow sensor, enabling 100% in-process control (IPC) and precise dosing for every single container. This helps support strong product yield and high traceability throughout production.

    1000x667_KombiFilling

    Combi filling station

    This patented solution is a highly flexible option for multi-product lines, directly addressing the growing demands of increasing product diversity in pharmaceutical manufacturing. It combines up to four different filling technologies on a single filling station, requires no additional trolleys, and uses a standard footprint that fits seamlessly into existing line layouts. Customers can start with one filling technology and expand the system step by step as your product portfolio and requirements evolve, making it a future-proof investment that grows with changing production needs.

    Compare our vial filling machines

    Overall 2 Solutions
    Output performance
    Format range
    Special features
    Changeover
    Filling systems
    Container types
    Barrier technologies and line integration
    Benefits
    ALF 5000 Vial Filling Machine
    ALF 5000
    Output performance
    600 c/min, 100 % IPC vials
    Format range
    Vials 2 to 500 milliliters, ampoules 1 to 30 milliliters
    Special features
    High-speed combi, gentle carry
    Changeover
    Fast tool-free changeover
    Filling systems
    Up to 12 heads, supports all filling systems
    Container types
    Vials, molded glass, ampoules
    Barrier technologies and line integration
    RABS or isolator, lyo option
    Benefits

    Best if you want:

    • Safe flexible high-speed combi line for ampoules and vials
    • 100 % IPC and modular platform for high-potent or complex aseptic products
    Specsheet
    FLC3000 Vial Filling Machine
    FLC 3000
    Output performance
    600 c/min, statistical IPC
    Format range
    Vials 2 to 500 milliliters
    Special features
    Compact, gentle vial transport
    Changeover
    Few parts, modular layout
    Filling systems
    Up to 12 heads, supports all filling systems
    Container types
    Vials, molded glass
    Barrier technologies and line integration
    RABS or isolator integration
    Benefits

    Best if you want:

    • Wide range, compact vial line for up to 500 milliliters
    • Compact medium to high output line for flexible layouts
    Specsheet
    Featured_Download_Teaser_FillingTechnologir

    Download the filling technologies brochure

    Use this brochure to compare filling technologies for different product requirements.

    • Match pump types to product and liquid behavior
    • Review 100% IPC and yield-focused functions
    • Explore PUPSIT and CIP/SIP options
    Download

    Pharmaceutical filling machines with greater control and yield

    1080x1080_PUPSITFilling2

    Automated PUPSIT for new or existing lines

    Verify sterile filters before use with less operator intervention.
    1080x1080_FillingTechnologies3

    100% IPC on every container

    Monitor fill weights continuously without separate inspection steps.
    1080x1080_ALF5000_2

    More correctly filled containers per batch

    Reduce product loss before, during and after production.
    1080x1080_CaseStudyPUPSIT
    Case Study

    Boehringer Ingelheim cuts setup time by up to 50%

    Facing Annex 1 PUPSIT requirements, frequent product changes and wide fill volume range, Boehringer Ingelheim worked with Syntegon and Sartorius on a single-use final filling setup. The result: up to 50% faster setup, robust PUPSIT execution and lower contamination risk.

     

    Read the full story
    1080x1080_Annex1
    Highlight Topic

    Annex 1

    Syntegon presents practical solutions to help pharmaceutical manufacturers ensure compliance and optimise their production lines.

    Find out about our innovative approaches to maximising product safety and efficiency, from PUPSIT and RABS to fully automated fill-and-finish solutions. 

    Learn more

    Your strategic lifecycle partner for Filling Technologies

    service-life-cycle
    Keep performance stable across the lifecycle

    Service agreements give you structured support from installation to routine operation, with fixed conditions and packages that match your production needs.

    Learn more
    service-life-uptime
    Cut risk in daily operations

    Maintenance planning, technical support and expert services reduce breakdowns, avoid unplanned downtime and protect reliability in day-to-day filling operations.

    Learn more
    service-future-ready
    Prepare your line for what comes next

    Modernizations, training and digital solutions give you more process transparency and keep your filling line ready for new products, new demands and more automation.

    Learn more

    Filling Technologies knowledge hub

    Filling Technologies
    Filling Technologies

    Use this brochure to select filling technologies for liquid pharmaceuticals and support the design of Annex 1-compliant fill finish lines.

    Download
    Filter Test Rack Brochure
    Filter Test Rack Brochure

    Discover how automated Filter Test Racks performs PUPSIT on single use filtration kits and record filter integrity tests directly in the batch protocol of the filling machine.

    Download
    Case Study Sartorius x Boehringer
    Case Study Sartorius x Boehringer

    Case study on an automated filter test rack for PUPSIT in final filling.

    Download

    Frequently asked questions

    The right pharmaceutical filling technology depends on product behavior, batch strategy and process requirements. Syntegon’s portfolio covers aqueous, highly viscous, shear-sensitive, potent and special applications. Peristaltic pumps are well suited for shear-sensitive products, rotary valve piston pumps suit aqueous and highly viscous liquids and rolling diaphragm pumps suit biologics and proteins. Combi filling stations can combine up to four filling technologies on one station for more flexibility.

    PUPSIT verifies that sterile filters are intact before product contact. Under EU GMP Annex 1, it has become an important measure for maintaining sterility and product safety in aseptic filling. It also reduces the risk of detecting filter defects too late, which is especially relevant for high-value pharmaceuticals. Automated PUPSIT can further reduce operator dependence and improve repeatability.

    Yes. Syntegon’s Filter Test Rack solutions can be integrated into new pharmaceutical filling lines or retrofitted on existing equipment, including third-party lines. The portfolio supports different containment and space requirements and can also be integrated into a CIP/SIP cabinet when needed. This gives teams a practical way to implement automated filter integrity testing without rebuilding the full line.

    Download portfolio overview

    100% in-process control means every container is monitored continuously during filling. In Syntegon filling systems, each container is weighed before and after filling, creating traceable fill-weight data at container level. This supports precise filling weights, consistent quality and full traceability across the filling process.

    Find out more

    100% IPC improves product yield by identifying underfills directly and supporting precise filling weights for every container. That reduces rejects and protects valuable product, especially in high-value applications. It also strengthens traceability and works alongside yield-focused functions such as MaxPro, which target product loss before, during and after production.

    Find out more

    Product loss in aseptic filling can be reduced through precise dosing, continuous fill-weight control and features designed for the main loss points in production. Syntegon offers 100% IPC and optional MaxPro functions such as Dose In/Dose Out, Twin Fill, Redose on Request and Run Empty to One Container. These functions help to reduce waste, avoid underfilled containers and increase the number of correctly filled containers per batch.

    Find out more

    Yes, if the pharmaceutical filling system is designed for flexibility. Syntegon’s portfolio includes different filling principles for different liquid behaviors, and its combi filling station can combine up to four filling technologies on one station. That allows manufacturers to start with one technology and expand step by step as product requirements change.

    Find out more

    CIP/SIP systems support pharmaceutical filling operations by simplifying cleaning and sterilization in reusable set-ups. In the brochure, CIP/SIP is linked to fast setup and changeovers, reduced cross-contamination risk and better long-term efficiency for reusable systems. Furthermore, a multi-use PUPSIT testing set-up can be added to the CIP/SIP cabinet. Some filling technologies, such as the rolling diaphragm pump, are also available in CIP/SIP versions. The right choice between single-use and CIP/SIP depends on factors such as batch size, product type and potency.

    Find out more
    Interested in pharmaceutical filling machines?

    Interested in pharmaceutical filling machines?

    Talk to a Syntegon expert to learn more about pharmaceutical filling machines.

    Learn more

    News

    Automatic tray loading for safe pharmaceuticals
    Automatic tray loading for safe pharmaceuticals

    Discover our automatic tray loading machines. Enhance output, ensure flexible format changes, and protect sensitive containers.

    Learn more
    Sustainability with sterilizers by Syntegon
    Sustainability with sterilizers by Syntegon

    Discover how Syntegon partners with pharmaceutical companies to balance sustainability, efficiency, and profitability in a highly regulated industry.

    Learn more
    Syntegon supports OSD manufacturing education
    Syntegon supports OSD manufacturing education

    Discover how Syntegon enhances pharmaceutical education with Dr. Marcus Knöll's insights at the University of Maryland's Tablets and Capsules Short Course.

    Learn more