Optimized syringe nest design for enhanced efficiency
Unlock your operational efficiency with an innovative polymer syringe nest
In today’s fast-paced pharmaceutical landscape, the demand for rapid, large-scale filling of vaccines, diluents, and blockbuster drugs in 1 ml long polymer syringes is at an all-time high. To stay competitive, manufacturers must achieve exceptional operational excellence and high-speed manufacturing that not only offers swift and efficient filling of syringes but also adheres to stringent quality standards and regulatory requirements.
High costs, less time and higher sustainability requirements - sound familiar?
Polymer Luer Lock syringes are commonly packed in a nest and tub system that holds 100 syringes per tub organized in a 10 x 10 array. As the demand for high-speed manufacturing intensifies, several pressing questions confront the industry:
- How can production costs be minimized while ensuring high quality and compliance with rigorous regulatory standards?
- Since the cycle time is influenced by the number of syringes in each nest, how can its configuration be optimized to streamline the filling process?
- How should we adapt to the increasing regulatory demands to reduce CO2 emissions while controlling the rising costs associated with waste management and inefficient packaging?
Navigating these challenges calls for transformative approaches that balance operational excellence with sustainability without compromising the quality of life-saving medications.
Transforming operational excellence with SCHOTT TOPPAC® Nest 160
SCHOTT TOPPAC® Nest 160 is the first and only system to hold polymer Luer Lock syringes in a 10 x 16 nest configuration, providing 160 1 ml long syringes per nest. This makes it ideal for the high-speed manufacture of vaccines, diluents, and dermal fillers.
Boost your efficiency
The innovative SCHOTT TOPPAC® Nest 160 features 160 cavities for prefillable polymer syringes, increasing to 60 syringes per nest. By offering a nest with 160 syringes, drug manufacturers benefit from an increased output compared to the standard setup. In the same cycle time, the new nest enables pharma companies to fill significantly more syringes per hour than the 100 syringes. This translates into an increase in efficiency by up to 67%.
Lower your manufacturing costs
Adopting the SCHOTT TOPPAC® Nest 160 can significantly cut your manufacturing costs compared to using the traditional SCHOTT TOPPAC® Nest 100. The innovative nest design not only reduces fill-and-finish costs, with lower personal costs at the line, but minimizes the number of pallets required per batch. This simplifies storage and retrieval processes and lowers associated time and labor costs. Furthermore, the new design reduces the amount of waste from nests, bags, and boxes, contributing to more efficient and sustainable operations.
Minimize your product carbon footprint
Switching to SCHOTT TOPPAC® Nest 160 significantly lowers your product’s carbon footprint by 17% compared to the traditional SCHOTT TOPPAC® Nest 100. An internal study revealed substantial reductions in environmental impact across several components, including the tub, nest, Tyvek® seal and inlay, bag, box, and wooden pallet. This advanced nest design is not just a step towards operational excellence but also a stride towards a greener, more sustainable production process.
Collaborating for an effortless filling process
The fully automated SFM5072 nest filling machine by Bausch+Ströbel ensures high precision in processing the SCHOTT TOPPAC® Nest 160. Equipped with two centering units, it seamlessly transports the nest to up to 16 filling stations and lane stopper supplies. This high-speed filling line significantly boosts output without altering the cycle time. Compared to the SCHOTT TOPPAC® Nest 100, the output speed has surged from 36,000 items per hour to 60,000 items per hour with the SCHOTT TOPPAC® Nest 160. If you operate an SFM5072 line, you can achieve these enhancements with only minor retrofitting!
Bausch+Ströbel’s SFM5072 filling line can fill 60,000 items per hour using the SCHOTT TOPPAC® Nest 160 (Image source: Bausch + Ströbel)
20+ years experience and proven track record with over 100 commercial customers
Four blockbuster drugs currently use SCHOTT TOPPAC® syringes
Market leaders in mRNA drugs choose SCHOTT TOPPAC® freeze syringes for their platform
Seamless filling guaranteed with Bausch+Ströbel’s high speed nest filling line
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