Syntegon & Vetter win PDA Drug Delivery Innovation Award for Versynta microBatch

Focus on loss-free filling and fast batch changeovers

Versynta microBatch is a highly flexible fully automated production cell with a gloveless isolator, the smallest possible dimensions, and a complete batch-to-batch changeover of less than two hours. Photo Syntegon

Together with Vetter, an international pharmaceutical service provider for injectables, Syntegon (formerly Bosch Packaging Technology) has won the PDA Drug Delivery Innovation Award. In the “Partnership Innovation” category, the Parental Drug Association (PDA) honors development projects by pharmaceutical and machine manufacturers that advance the production of (bio)pharmaceuticals. The collaboration between Vetter and Syntegon resulted in Versynta microBatch, a highly flexible and fully automated production cell with a gloveless isolator, the smallest possible dimensions, and a complete batch-to-batch changeover of less than two hours.

Joint development for benefit of patients

“There is a stronger focus on patient needs than ever before,” says Vetter managing director Thomas Otto. “The continuous progress in our industry towards greater patient well-being is a positive development and, at the same time, brings additional challenges for pharmaceutical manufacturers and service providers. Pharmaceutical and biotech companies require highly effective drugs for significantly smaller patient groups. For their service providers, this means creating new concepts for filling and process design while meeting increasing quality requirements. We have worked closely with Syntegon to develop a new industry standard for small-scale filling processes.”

“We are also observing a growing demand for highly flexible filling solutions for small batches – and we know that innovations thrive best when many years of experience from different areas are combined,” says Dr Alexander Giehl, head of the Pharma Liquid & Inspection business cluster at Syntegon. “Our name says it all: the ‘Syn’ in Syntegon stands for synergy. The joint development with Vetter brings improvements for our customers and ultimately for the patients, in line with our mission ‘processing and packaging for a better life’.”

Versynta microBatch: a new concept for very small batches

With Versynta microBatch, Syntegon and Vetter are developing a fully automated, highly flexible production cell designed to fill and close a wide variety of containers. Syringes, cartridges, and vials made of glass or plastic can be filled with virtually no product loss. The gloveless isolator with integrated air treatment significantly reduces the risk of contamination from machine operators. Fully automated filling and 100 percent in-process control ensure continuously high quality. The result is an innovative, GMP-compliant system that sets new standards in small-batch filling with an output of 120 to 500 containers per hour.

Versynta microBatch is expected to be launched in spring 2022 at Achema.

Syntegon Technology is a global process and packaging technology provider. Formerly the packaging division of the Bosch Group, the company, headquartered in Waiblingen (Germany), has been offering complete solutions for the pharmaceutical and food industries for over 50 years. About 6,000 employees at 30 locations in more than 15 countries generated total revenue of EUR 1.3 billion (approximately Rs 11,244 crore) in 2020. The portfolio of intelligent and sustainable technologies includes stand-alone machines, as well as complete systems and services. Fields of application in the pharmaceutical industry are the production, processing, filling, inspection and packaging of liquid and solid pharmaceuticals (for example syringes and capsules). In the food industry, the portfolio includes process technology for confectionery as well as packaging solutions for dry foods (for example bars, bakery products, and coffee), frozen foods, and dairy products.

The Covid-19 pandemic led to the country-wide lockdown on 25 March 2020. It will be two years tomorrow as I write this. What have we learned in this time? Maybe the meaning of resilience since small companies like us have had to rely on our resources and the forbearance of our employees as we have struggled to produce our trade platforms.

The print and packaging industries have been fortunate, although the commercial printing industry is still to recover. We have learned more about the digital transformation that affects commercial printing and packaging. Ultimately digital will help print grow in a country where we are still far behind in our paper and print consumption and where digital is a leapfrog technology that will only increase the demand for print in the foreseeable future.

Web analytics show that we now have readership in North America and Europe amongst the 90 countries where our five platforms reach. Our traffic which more than doubled in 2020, has at times gone up by another 50% in 2021. And advertising which had fallen to pieces in 2020 and 2021, has started its return since January 2022.

As the economy approaches real growth with unevenness and shortages a given, we are looking forward to the PrintPack India exhibition in Greater Noida. We are again appointed to produce the Show Daily on all five days of the show from 26 to 30 May 2022.

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