ZONESUN ZS-FAL180SY1 Automatic Catheter Flush Syringe Assembly Filling Capping Machine

Description

The ZONESUN ZS-FAL180SY1 is an automated catheter flush syringe assembly and filling system for plastic prefilled syringe production. It completes component feeding, syringe assembly, siliconization, filling and tip-cap closure with reduced manual handling.

During filling, each syringe is inverted so the ceramic pump can dispense liquid from the tip side. This process is designed to limit trapped air and maintain stable filling performance across production batches.

The line processes syringe sizes from 0.5 to 50 mL and provides adjustable filling volumes from 0.3 to 50 mL. Changeable molds and filling pumps allow the system to be configured for different syringe formats and dosage requirements.

Main Advantages

• Continuous syringe assembly and filling
• Tip-side filling with inverted syringes
• Reduced residual air
• Accurate ceramic pump filling
• Automatic cap sorting and placement
• Changeable syringe positioning molds
• Medical-grade product-contact materials
• Touchscreen production control
• Optional clean-air protection
• Suitable for standalone or line operation

Applications

Suitable for prefilled catheter flush syringes and other liquid products packaged in plastic prefilled syringes. Final configuration depends on the syringe structure, filling volume, liquid properties and cleanliness requirements.

Parameter

• Machine Model: ZS-FAL180SY1
• Machine Voltage: 380V/220V, 50–60 Hz
• Machine Power: 6 kW
• Applicable Syringe Size: 0.5–50 mL
• Syringe Mold: Different syringe sizes require different molds
• Filling Range: 0.3–50 mL
• Filling Pump: Different filling volumes may require changing the filling pump
• Number of Filling Heads: 1
• Number of Capping Heads: 1
• Filling Accuracy: ≤ ±1%
• Production Capacity: 1,800–2,400 Syringes/Hour
• Compressed Air Requirement: 0.55–0.75 MPa, 20 L/s
• Machine Dimensions: About L3400 × W950 × H1800 mm (Excluding Laminar Flow Hood)
• Machine Weight: About 1100 kg

Automatic Feeding Station

Automatically sorts and transfers syringe components into the production line, reducing manual handling and improving production consistency.

Siliconization & Assembly Station

Japanese micro-atomization spray valves deliver precise, splash-free siliconization, while the assembly mechanism completes stopper installation in a synchronized process.

Top Filling Structure

The syringe is inverted before filling, allowing the product to be filled from the syringe tip to minimize residual air inside the barrel. Ceramic pump provides accurate volumetric filling.

Vibratory Cap Feeding System

Manufactured from polished SUS316L stainless steel, the vibratory bowl automatically sorts and supplies caps without creating difficult-to-clean dead corners.

Automatic Capping Station

Servo-controlled capping mechanisms ensure stable assembly quality and can be configured for different prefilled syringe cap structures.

Why Choose the ZONESUN ZS-FAL180SY1?

✅ 1,800–2,400 Syringes/Hour — Efficient Automated Production: Integrates syringe feeding, siliconization, assembly, filling, cap feeding, capping, and reject removal into one continuous process, reducing manual operation and improving production efficiency.

✅ Ceramic Pump Filling — ≤±1% Dosing Accuracy: The ceramic volumetric pump provides precise and repeatable liquid dosing for prefilled syringe production, supporting filling volumes from 0.3 to 50 mL.

✅ Inverted Tip Filling — Reduced Residual Air: Syringes are inverted before filling so the product enters from the syringe tip, helping minimize residual air inside the barrel and improve filling consistency.

✅ Micro-Atomization Siliconization — Precise & Splash-Free Coating: Japanese micro-atomization spray valves provide controlled siliconization while minimizing splashing, followed by synchronized stopper assembly.

✅ SUS316L Cap Feeding System — Hygienic Automatic Supply: The polished SUS316L vibratory bowl automatically sorts and supplies caps while reducing hard-to-clean dead corners for improved hygiene.

✅ Servo-Controlled Capping — Stable Assembly Quality: Servo-controlled capping provides consistent assembly performance and can be configured to accommodate different prefilled syringe cap structures.

✅ Optional Class 100 Laminar Flow Hood — Higher Cleanliness Capability: The production line can be equipped with an optional Class 100 laminar flow hood for applications requiring a higher-cleanliness operating environment.

Ideal Applications

Catheter Flush Syringes: Ideal for automatic production of prefilled catheter flush syringes requiring accurate liquid dosing, low residual air, and consistent cap assembly.

Plastic Prefilled Syringes: Suitable for various plastic prefilled syringe products within the supported 0.5–50 mL syringe size range.

Medical Device Production: Designed for medical device manufacturers requiring automated syringe feeding, siliconization, assembly, filling, and capping processes.

Pharmaceutical Filling: Suitable for applicable pharmaceutical liquid products requiring precise ceramic pump dosing and hygienic product-contact components.

High-Cleanliness Production: Optional Class 100 laminar flow hood supports production environments requiring enhanced cleanliness around the filling and capping process.

Automated Syringe Production Lines: Provides an integrated solution for manufacturers seeking to combine syringe component feeding, assembly, filling, capping, and reject removal into a continuous automated workflow.