Syntegon: Automatic tray loading for safe pharmaceuticals

Our automatic tray loading machines are true all-rounders: They help pharmaceutical manufacturers increase output, support flexible format changes, and protect sensitive containers throughout the packaging and transport process.

In pharmaceutical and biotech manufacturing, every single handling step matters. Even minor handling errors can lead to costly delays, higher reject rates, and product loss. At the same time, manufacturers must process diverse container formats and filling volumes while complying with strict GMP requirements. With the automatic tray loading solutions from Syntegon, manufacturers benefit from efficient, flexible, and reliable tray loading technology for vials and cartridges that expertly handle the challenges of today’s production environments.

Fast and precise tray loading for sensitive containers

Our GLT and TLU-C tray loading systems combine high-speed performance, precise product handling, and GMP-compliant design. Thanks to advanced robotics and in-line conveyer technology, they ensure full traceability as well as smooth and gentle transport that reduces breakage, rejects, and product loss.

The horizontal vial tray loader GLT supports outputs of up to 24,000 vials per hour (400 per minute). Its unique loading concept aligns vials without guides, reducing faulty runs. Flexible loading patterns and tray formats, combined with fewer format parts, enable fast and efficient changeovers. A servo-based vial count ensures every container is accounted for.

Meanwhile, the cartridge tray loader TLU-C processes up to 36,000 cartridges per hour (600 per minute). Cap or stopper UCI engravement (Unique Container Identification), integrated quality inspection of containers (e.g., vision control), reject discharge outside the clean room area, and a separate sampling station support maximum quality control. Tiltable plates make tray handling more convenient and ergonomic for operators.

Tray loading – your benefits at a glance

• Gentle handling and minimized rejects with robotics and conveyor technology
• Full traceability thanks to container tracking solutions
• Flexibility for changing demands with fast changeovers and adaptable configurations
• GMP-compliant design supports safe and hygienic pharmaceutical production
• Smooth integration into production lines

Flexible automation for efficient pharmaceutical production

As production requirements continue to evolve, manufacturers require automation systems that quickly adapt to changing formats, products, and batch sizes. Our tray filling systems are specifically designed for flexible production setups. Furthermore, they seamlessly integrate into your line or can be individually adapted to your production.

Need support selecting the machine that best meets your requirements? Let’s find the right setup together! Our lifecycle services cover everything, from initial consultation and installation to long-term maintenance services and technical support. Get in contact with our experts now to find your individual solution for tray loading!

This article was originally published by Syntegon.