Achema Launch: New Settle Plate Changer from Syntegon for Automated viable Monitoring

* Syntegon launches patented new development for the pharmaceutical industry
* Focus on Annex 1 compliance: reducing machine stops, manual intervention, and contamination risks in the aseptic filling process
* Seamless and sustainable integration into new and existing equipment

 

Waiblingen (Germany), June 17, 2024. There was a lot to see at the Syntegon booth at Achema 2024. The company presented an important new development that generated a great deal of interest among pharmaceutical manufacturers: the patented Settle Plate Changer (SPC) for automated viable monitoring in the aseptic filling process. With this innovative solution, Syntegon will support customers in complying with the latest Annex 1 both for new and existing equipment.

Environmental monitoring has become even more important in the context of EU GMP Annex 1.

 
Higher machine availability thanks to automation
“Environmental monitoring is essential in aseptic manufacturing and has become even more important in the context of EU GMP Annex 1,” says Steffen Gröber, Global Product Manager Service at Syntegon. Settle plates may be exposed to cleanroom air for a maximum of four hours and must then be replaced to ensure consistent sampling for liquid filling operations. With the new robotic handling unit from Syntegon, this step can now be performed automatically, siginificantly reducing the previously required production interruptions. “Thanks to the SPC, machines only need to be stopped once a day for viable monitoring, which results in noticeably higher machine availability of up to 300 hours per year and therefore more sustainable processes,” says Gröber. Process reliability and traceability can also be increased thanks to optional barcode scanning.

The compact Settle Plate Changer is not only available for Syntegon machines but for all machine brands, types, and controls.

 
Reducing manual intervention and contamination risks
In addition to significant advantages for productivity, the Settle Plate Changer fulfills another important Annex 1 requirement: reducing manual operator intervention in the process zone for environmental monitoring by 80 percent and thereby minimizing the risk of contamination to a minimum. In the second chapter of Annex 1, automation and robotic systems are particularly emphasized under the keyword “appropriate technologies” for maintaining sterility. “The SPC reflects our commitment to meeting regulatory requirements at all times and to always putting customer needs first. Even before Annex 1 came into force, we started developing our automated solution and secured the patent,” says Muhammed Ali Turac, Project Manager Automation at Syntegon Service.
 

 
The new patented Settle Plate Changer SPC from Syntegon automates viable monitoring and reduces production interruptions and human intervention in the process zone to a minimum.
 

Seamless and sustainable integration in new and existing machines
The Settle Plate Changer from Syntegon is available both with the purchase of a new machine and as a retrofit for existing equipment. “What's more, it can also be seamlessly integrated into all machines and control systems from third-party suppliers,” Steffen Gröber emphasizes. “As a result, we ensure that the service life of existing equipment is increased and pharmaceutical manufacturers can run more sustainable processes thanks to reduced downtimes.”
 
The new SPC from Syntegon will also be presented at the following trade shows:
* CPHI Milan, Italy, October 8-10, 2024, booth 18C33
* Pack Expo Chicago, USA, November 3-6, 2024, West Hall, booth 18099
* PMEC India, Delhi, November 26-28, 2024, booth 12.A03
 
Further information on the SPC can be found here.
 
About Syntegon
Processing and packaging for a better life – this is what 6,300 Syntegon employees work for every day. Be it with individual machines, systems, or services, Syntegon helps its customers in the global pharmaceutical and food industries to improve people's lives. The company, which is headquartered in Waiblingen, Germany, looks back on more than 160 years of experience and achieved annual sales of 1.5 billion EUR in 2023. In the pharma sector, the company’s intelligent solutions enable the safe and high-quality production, processing, filling, inspection, and packaging of liquid and solid pharmaceuticals. In the food industry, Syntegon’s flexible and reliable technologies produce and pack confectionery, dry food, frozen food, and dairy products. With 1,200 service experts and a comprehensive service portfolio throughout the entire machine lifecycle from spare parts management to digital line optimization, Syntegon lays the foundation for smooth production processes for all customers. More than 39 sites in almost 20 countries keep a firm eye on Syntegon’s impact on the environment and society. Syntegon is a leader in the development of sustainable packaging solutions, reduces the energy consumption of its machines and pursues ambitious goals to lower its emissions. www.syntegon.com