Optimized polymer syringe nest design for operational efficiency

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.

The challenge

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.

The solution

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.

SCHOTT TOPPAC® Nest 160 filled with 1 ml polymer syringes

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%.

Exploded view of the SCHOTT TOPPAC® Nest 160 syringe system

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.

Open tub of the SCHOTT TOPPAC® Nest 160 system filled with 1 ml polymer syringes

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.

Dr. Nina Krautwurst - Global Product Manager Polymer Syringes, SCHOTT Pharma
For the SCHOTT TOPPAC® Nest 160 project, we collaborated closely with Bausch+Ströbel to guarantee seamless integration with their high-speed filling lines. With minimal modifications, these lines can efficiently fill up to 160 syringes per nest.
The compatibility

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!

Annotated illustration of a high-speed filling line from Bausch+Ströbel

Bausch+Ströbel’s SFM5072 filling line can fill 60,000 items per hour using the SCHOTT TOPPAC® Nest 160 (Image source: Bausch + Ströbel)

The advantages
20+ years experience and track record with over 100 commercial customers icon

20+ years experience and proven track record with over 100 commercial customers

Four blockbuster drugs using SCHOTT TOPPAC® syringes icon

Four blockbuster drugs currently use SCHOTT TOPPAC® syringes

Leading mRNA market leaders have selected SCHOTT TOPPAC® freeze for their platform icon

Market leaders in mRNA drugs choose SCHOTT TOPPAC® freeze syringes for their platform

Seamless filling guaranteed with Bausch + Ströbel high speed nest filling line icon

Seamless filling guaranteed with Bausch+Ströbel’s high speed nest filling line

Get in touch

Dr. Nina Krautwurst

Dr. Nina Krautwurst

Global Product Manager Polymer Syringes

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