ZONESUN ZS-DM1 Automatic Prefilled Syringe Denesting Machine for Syringe Filling Lines

Description

The ZONESUN ZS-DM1 is a fully automatic prefilled syringe denesting machine designed to remove syringes from nest tubs and transfer them one by one into downstream filling and stoppering lines. It supports BD, BG, SCHOTT, SCF, and other standard nest formats, with custom tooling available for special specifications. Built on a SUS304 stainless steel frame with SUS316L and medical-grade silicone product-contact parts, it meets stringent pharmaceutical hygiene and material standards.

The ZS-DM1 features a PLC + touchscreen control system with real-time monitoring, fault detection, and alarm functions for simplified maintenance. Its modular design supports both standalone operation and seamless inline integration with syringe filling and stoppering equipment. An optional Grade A laminar flow hood is available for facilities requiring higher aseptic manufacturing cleanliness levels.

Parameter

• Machine Model: ZS-DM1
• Voltage: 380V / 220V, 50/60 Hz
• Total Power: 0.8 kW
• Applicable Syringe Specifications: 0.5–10 ml (Different specifications require mold replacement)
• Compressed Air: 0.55–0.75 MPa, 15 L/S
• Machine Size (L×W×H): 2230 × 900 × 1800 mm (Without laminar flow hood)
• Machine Weight: 400 kg

Automatic Syringe Extraction Unit

Automatically removes prefilled syringes from nest trays and transfers them smoothly without damaging the barrels.

Tilting Discharge Mechanism

Tilts the syringe holding assembly and guides syringes smoothly into the infeed rail of the downstream filling and stoppering machine.

Aseptic Glove Port Design

Allowing aseptic manual adjustments, sampling, and interventions through integrated glove ports without directly exposing the sterile process environment.

Modular Control System

The machine uses modular electrical components to simplify operation and integration with syringe filling, stoppering, and other pharmaceutical equipment.

Optional Grade A Laminar Flow Hood

An optional Grade A laminar flow hood creates a localized clean airflow area above the syringe processing zone, helping meet higher aseptic manufacturing requirements.

Key Features

✅ Multi-Format Nest Compatibility: Supports BD, BG, SCHOTT, SCF, and other standard nest tub formats, with custom tooling available for non-standard syringe specifications.

✅ Pharmaceutical-Grade Materials: SUS304 machine frame with SUS316L and medical-grade silicone product-contact parts, fully compliant with pharmaceutical hygiene and material standards.

✅ Gentle, Damage-Free Extraction: Automated extraction mechanism removes syringes from nest trays without contacting or stressing the barrel, preserving prefilled product integrity.

✅ Smooth Downstream Transfer: Tilting discharge mechanism guides syringes directly into the infeed rail of filling and stoppering lines, ensuring continuous, jam-free production flow.

✅ Aseptic Glove Port Access: Integrated glove ports allow operators to perform manual adjustments, sampling, and interventions without breaking the sterile process barrier.

✅ PLC + Touchscreen Control: Real-time monitoring, fault detection, and alarm functions simplify operation and reduce maintenance response time on the production floor.

✅ Modular Design for Flexible Integration: Operates standalone or integrates inline with syringe filling, stoppering, and capping equipment via modular electrical architecture.

✅ Optional Grade A Laminar Flow Hood: Available upgrade for facilities requiring ISO 5 / Grade A localized clean airflow above the syringe processing zone.

✅ Wide Syringe Size Range: Handles 0.5–10 ml prefilled syringes with mold changeover, supporting multiple product formats on a single machine platform.

Applications

• Prefilled Syringe Filling Lines: Automated denesting and infeed of prefilled syringe barrels into filling and stoppering machines for injectable drug manufacturing.
• Vaccine & Biologic Manufacturing: Aseptic denesting of glass and polymer syringes for human and veterinary vaccine filling under GMP-compliant conditions.
• Insulin & Hormone Injectables: High-precision syringe feeding for small-volume parenteral (SVP) filling lines handling insulin, hormones, and other sensitive biologics.
• Ophthalmic & Specialty Injectables: Gentle extraction and transfer of delicate syringe formats used in ophthalmic drug delivery and specialty injectable products.
• Contract Development & Manufacturing (CDMO): Flexible multi-format denesting for CDMOs handling diverse syringe specifications and frequent product changeovers.
• Veterinary Injectable Packaging: Denesting and feeding of veterinary prefilled syringes for animal health drug filling and aseptic packaging lines.
• Export & Regulated Markets: Machine design and GMP-compliant materials support compliance with WHO, EU GMP, FDA, and other international pharmaceutical manufacturing regulations.