With Versynta FFP, Syntegon Technology offers a new, modular small-batch solution for liquid pharmaceuticals.
Syntegon Technology is expanding its portfolio and bundling filling solutions for small and micro batches under the name Versynta. This is the company's response to a trend in the pharmaceutical industry: more and more high-priced biotech drugs for small target groups require highly specialised filling solutions. Flexible filling solutions, which achieve a high product yield at a low output.
Versynta offers integrated flexibility
The new solution is a Individually configurable machine together with an integrable isolator for filling aseptic and highly potent liquid active ingredients. The FFP stands for Flexible Filling Platform.
„This allows us to offer pharmaceutical manufacturers, development laboratories and biotech start-ups a combination of standardisation and high modularity with short delivery times,“ says Klaus Ullherr, Senior Product Manager at Syntegon. The platform is based on pre-developed and tested modules that can be flexibly combined. Versynta FFP processes up to 3,600 containers per hour and has 100 per cent in-process control.
According to the company, Versynta FFP can be easily installed on Various container types such as vials, syringes and cartridges and Different filling systems including disposable solutions. Instead of entire modules, only format parts need to be replaced. It is also possible to process high-potency products vacuum-free.
Safe, gentle transport is ensured by the Pharma Handling Unit, a four-axis robot developed by Syntegon, which transfers the containers from one station to the next without glass-to-glass contact. The laminar flow-optimised design ensures that the air flow can reach and flow around the containers unhindered („first air supply“).
First customer applications
„Syntegon is primarily known for medium and high-performance systems. However, we can also look back on many years of experience and more than 60 successful customer references in the small batch sector,“ explains Dr Alexander Giehl, site manager Crailsheim. „We are pooling this experience with Versynta.“
Customers are offered a streamlined complete solution for the entire filling process from a single source, including an integrated isolator and ventilation technology. Versynta FFP is suitable for filling aseptic and highly potent products with short cycle times. Pressure and zone concepts can be flexibly customised.
Syntegon works with the international pharmaceutical company Ferring Pharmaceuticals on the first installation of Versynta FFP. A solution for even smaller batches is also planned. The Versynta microBatch is already being trialled with a customer and is due to be launched on the market next year.
„In micro batch applications, maximum product yield and fast batch changes are even more important. The biggest challenge was to design the isolator of the production cell without glove ports,“ explains Ullherr. The result is a highly flexible and fully automated production cell with the smallest possible dimensions and a complete batch-to-batch changeover time of less than two hours.
Syntegon will be presenting the new Versynta platform on 15 and 16 June at Achema Pulse and at the Syntegon virtual event from 22 to 24 June.
Source: Syntegon Technology
