Press Releases

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.

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.

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.

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.”