Syntegon Unveils New Aseptic Filling Line
During Pharmatag 2025, Syntegon presented its new SynTiso aseptic filling line at Pharmatag 2025, which has been developed in collaboration with partners from the pharmaceutical industry to meet the increasing need for flexibility, contamination control, and Annex 1 compliance.
Pharmaceutical packaging specialist Syntegon has unveiled its latest aseptic filling line, SynTiso, at the Pharmatag 2025 event in Crailsheim (1). Developed to address the evolving needs of pharmaceutical manufacturers, the system claims to boost operational efficiency and availability by maximizing product yield and minimizing operator intervention. Created in collaboration with two pharmaceutical partners, the aseptic filling line features 100 percent in-process control (IPC) and can handle up to 600 containers per minute — including syringes, vials, and cartridges.
“As a strategic partner to the pharmaceutical industry, we will revolutionize filling operations together with our customers,” said Stephan März, Executive VP Pharma Liquid at Syntegon, in a company press release (1).
“But we go one step further with SynTiso,” added Markus Heinz, Product Manager at Syntegon, in the press release (1). “The robots are generally located as far away from the process as possible and are only used for aseptic setup and as needed. The position of the robots also minimizes particles in the aseptic area, which in turn significantly reduces the risk of contamination.”
“The result is impressive: this line concept brings us a big step forward toward our vision of a virtually empty isolator, which will deliver significantly greater flexibility and faster availability,” confirmed März (1). A “virtually empty isolator” is an aseptic manufacturing environment that contains minimal mechanical components or robotic elements within the critical aseptic zone.
“This is more than just another high-speed filler,” said Heinz (1). “We’ve rethought how aseptic zones function, and SynTiso reflects that — from its architecture to its monitoring systems.”
The concept is likely to appeal to pharmaceutical manufacturers who are increasingly shifting toward ready-to-use (RTU) containers for small batches and high-value therapies. The contactless, suspended transport of the aseptic filling line generates no particles and facilitates cleaning and maintenance due to a smaller number of components within the isolator.
“Together with our partners, we’ve embedded pharmaceutical process thinking into the heart of the design,” remarked März (1). “It’s a shift from retrofitting automation into legacy systems to designing around pharmaceutical requirements from the ground up.”
The launch of SynTiso comes as manufacturers across the industry are modernizing their aseptic operations in line with recent regulatory frameworks updates (2). As demand for faster and more flexible production grows, fully automated and modular systems are likely to attract attention from large-scale vaccine and biologics manufacturers, and CDMOs seeking scalable, Annex 1-compliant solutions.
Whether SynTiso becomes the new standard remains to be seen, but Syntegon’s bet on cleanroom automation and modularity indicates a shift in where the industry is headed.
References
Syntegon. New SynTiso line concept from Syntegon revolutionizes liquid pharmaceutical filling. Press Release, May 28, 2025.
European Commission. EU GMP Annex 1: Manufacture of Sterile Medicinal Products. EudraLex Volume 4, August 2022.