Description
The ZONESUN ZS-DM1 Automatic Prefilled Syringe Denesting Machine is designed to remove syringes from nest tubs and transfer them individually to downstream filling, stoppering or handling equipment. It supports common prefilled-syringe nest formats and can be configured with matching tooling for different syringe specifications.
The machine combines an automatic syringe extraction unit, tilting discharge mechanism, PLC touchscreen control and modular line-integration structure. It supports syringe sizes from 0.5–10 ml with mold replacement for different formats, and can be configured for standalone use or integration into compatible prefilled-syringe processing lines.
Technical Specifications
| Model | ZS-DM1 |
|---|---|
| Power Supply | 220V / 380V, 50/60 Hz |
| Total Power | 0.8 kW |
| Applicable Syringe Size | 0.5–10 ml |
| Format Change | Different syringe specifications require matching mold/tooling |
| Compressed Air | 0.55–0.75 MPa, 15 L/s |
| Machine Size | 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
✅ Pharmaceutical-Grade Materials: SUS304 frame with SUS316L and medical-grade silicone product-contact parts — fully compliant with GMP and pharmaceutical manufacturing standards.
✅ Multi-Format Compatibility: Supports BD, BG, SCHOTT, SCF, and other standard nest formats; custom molds available for special syringe specifications (0.5–10 ml).
✅ Gentle, Damage-Free Transfer: Precision extraction and tilting discharge mechanism ensures syringes are transferred without barrel damage or contamination.
✅ Aseptic Glove Port Integration: Enables manual interventions and sampling without breaking the sterile barrier of the process environment.
✅ PLC Touchscreen Control: Real-time monitoring, fault detection, and alarm system for simplified operation and rapid troubleshooting.
✅ Modular & Flexible Design: Operates standalone or integrates inline with filling, stoppering, and other downstream pharmaceutical equipment.
✅ Optional Grade A Laminar Flow Hood: Upgradeable for higher cleanliness classifications to meet stricter aseptic processing requirements.
✅ Customizable: Special syringe formats and line configurations supported — send samples for tailored solutions.
Applications
- Prefilled Syringe Manufacturing: Automated denesting for high-speed prefilled syringe filling and stoppering lines in pharmaceutical production.
- Biologics & Vaccine Production: Aseptic handling of syringes for injectable biologics, vaccines, and biosimilars requiring strict contamination control.
- Ophthalmic & Specialty Injectables: Precise, gentle syringe transfer for small-volume parenteral (SVP) and ophthalmic drug products.
- Contract Manufacturing Organizations (CMOs): Flexible multi-format compatibility for CMOs handling diverse syringe types and batch sizes.
- Hospital & Clinical Pharmacy: Automated syringe preparation for high-volume clinical compounding and sterile drug preparation environments.
How the Syringe Denesting Process Works
The nest tub is positioned at the denesting station, where the machine extracts syringes from the nest and transfers them in a controlled sequence. The tilting discharge mechanism then guides the syringes toward the downstream rail or transfer point for the next filling, stoppering or handling process.
Best-Suited Applications
The ZS-DM1 is intended for prefilled-syringe production environments that require automatic denesting before downstream processing. It can be evaluated for different standard nest formats and syringe sizes within the listed 0.5–10 ml range.
Syringe Denesting vs Manual Nest Removal
Manual nest removal depends on operator handling and is more suitable for low-volume or development work. Automatic denesting provides a repeatable transfer process and is better suited to production lines that require consistent syringe feeding into downstream equipment.
Standalone vs Inline Configuration
The machine can be used as a standalone denesting station or integrated with compatible downstream filling, stoppering and handling equipment. The transfer height, line direction, syringe format and interface should be confirmed together with the complete production-line layout.
Before Ordering, Please Confirm
- Syringe brand and nest/tub format
- Syringe volume and dimensions
- Nest quantity and layout
- Required production speed
- Downstream filling or stoppering machine information
- Transfer height and production-line direction
- Required voltage and frequency
- Available compressed-air supply
- Whether a laminar-flow hood or other clean-area configuration is required
Frequently Asked Questions
What syringe sizes can the ZS-DM1 handle?
The listed syringe range is 0.5–10 ml, with matching tooling required for different specifications.
Can it work with different nest formats?
Yes. Different standard formats can be evaluated, and tooling may need to be customized according to the actual syringe and nest system.
Does the machine fill syringes?
No. The ZS-DM1 is a denesting machine. It removes syringes from nests and transfers them to compatible downstream processing equipment.
Can it connect to a filling and stoppering machine?
Yes. It is designed for integration with compatible downstream syringe filling and stoppering equipment.
Is a laminar-flow hood available?
An optional laminar-flow hood configuration is listed for applications that require a controlled local airflow environment.
Why are syringe and nest samples required?
Syringe geometry, nest layout and transfer requirements determine the correct extraction tooling and machine interface.
Need Help Confirming the Syringe Denesting Setup?
Send us your syringe samples, nest/tub samples or drawings, syringe size, target speed and downstream equipment information. We can help confirm the suitable ZS-DM1 configuration.
