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Advanced features
In addition to these core functions, our systems can be equipped with advanced features to enhance operational efficiency and product quality:
- Infeed tub or (WIP) tray buffering with FIFO Policy: Ensures the first-in, first-out processing of syringes, maintaining orderly production flow.
- Decoding of pre-printed data on the tub or tray by a vision system: Automated vision systems decode and verify data printed on tubs, ensuring traceability and reducing errors.
- Automated denesting from tub or tray: Efficiently removes nests from tubs to streamline the assembly process.
- Empty tub / tray and nest stacking units: Provides organized stacking of empty tubs and nests, facilitating continuous operation.
- Gentle transfer of syringes onto the unload guide: Ensures careful handling of syringes, reducing the risk of damage.
- Also available in no Glass-To-Glass contact version: Offers a version with no glass-to-glass contact, minimizing the risk of breakage and contamination.
Syringe assembly machines for every production scale
Our SAP-M platform has been specifically developed to support a smooth growth path while maintaining product quality, process consistency, andassembly parameters. The entire range utilizes the same assembly principles, making the upscaling process highly accessible:
- SAP-M (Syringe Assembly Platform – Manual): A compact desktop solution for low-volume production, development activities, and clinical batches.
- SAP-S (Semi-Automatic Syringe Assembly Platform): A flexible semi-automatic system designed for medium production volumes.
- SAP-A (Automatic Syringe Assembly Platform): A fully automatic solution for high-volume, 24/7 syringe assembly operations.
Because the same assembly technology is applied throughout the platform, process knowledge, assembly parameters, and validation data can be leveraged when moving to a higher-capacity system. This significantly reduces implementation risks and helps accelerate time-to-production. Our machines are robust, reliable, and flexible, allowing for various production line layouts. They can be integrated with both conventional conveyor systems and no-glass-to-glass-contact transport solutions, ensuring safe and efficient handling of prefilled syringes throughout the assembly process.
The Syringe Assembly Process
Our syringe assembly solutions can automate the complete assembly process of prefilled syringes. Depending on the application, the process may include denesting, plunger rod insertion through rotation or torque-controlled assembly, backstop and finger flange fitting, safety device assembly, labeling, and vision inspection. Integrated quality controls verify component presence, orientation, assembly quality, and label correctness, ensuring reliable and compliant syringe production.
Optional modules and configurations
Assembly for glass and plastic syringes
The SAP platform can be configured for the assembly of both glass and plastic prefilled syringes. By handling syringes in a horizontal position throughout the assembly process, the platform provides stable and controlled product handling across different syringe formats. GTE also offers a version with no glass-to-glass contact, designed for products where careful handling is critical. This helps reduce the risk of syringe breakage, cosmetic damage and particle generation during production. By minimizing unnecessary contact between components, manufacturers can further lower contamination risks while maintaining product quality. The same validated assembly principles are used across the SAP platform range, enabling consistent assembly performance from development and clinical batches through to commercial production. Optional inspection and verification modules can be integrated to further support quality assurance requirements.
Built for your production: from clinical trial to full line
The SAP platform is designed for manufacturers at different stages of growth, from start-ups and clinical trial production to established pharmaceutical companies and CDMOs. Its modular design makes it suitable for small batches, pilot production and scale-up projects, while providing a clear path towards higher levels of automation as production demands increase. As product portfolios become more diverse, manufacturers need equipment that can efficiently handle frequent changeovers and varying batch sizes. Since 2000, GTE has specialised in high-mix, low-volume production environments, helping customers balance flexibility, quality and productivity. Whether you are introducing a new drug delivery device, supporting clinical studies or preparing for commercial production, the SAP platform can be configured to match your current requirements and future growth plans.
Interested in finding out how high-mix, low-volume manufacturing can improve your production process? Read our knowledge articles.
Read our articles
Optional modules and configurations
Assembly for glass and plastic syringes
The SAP platform can be configured for the assembly of both glass and plastic prefilled syringes. By handling syringes in a horizontal position throughout the assembly process, the platform provides stable and controlled product handling across different syringe formats. GTE also offers a version with no glass-to-glass contact, designed for products where careful handling is critical. This helps reduce the risk of syringe breakage, cosmetic damage and particle generation during production. By minimizing unnecessary contact between components, manufacturers can further lower contamination risks while maintaining product quality. The same validated assembly principles are used across the SAP platform range, enabling consistent assembly performance from development and clinical batches through to commercial production. Optional inspection and verification modules can be integrated to further support quality assurance requirements.
Built for your production: from clinical trial to full line
The SAP platform is designed for manufacturers at different stages of growth, from start-ups and clinical trial production to established pharmaceutical companies and CDMOs. Its modular design makes it suitable for small batches, pilot production and scale-up projects, while providing a clear path towards higher levels of automation as production demands increase. As product portfolios become more diverse, manufacturers need equipment that can efficiently handle frequent changeovers and varying batch sizes. Since 2000, GTE has specialised in high-mix, low-volume production environments, helping customers balance flexibility, quality and productivity. Whether you are introducing a new drug delivery device, supporting clinical studies or preparing for commercial production, the SAP platform can be configured to match your current requirements and future growth plans.
Interested in finding out how high-mix, low-volume manufacturing can improve your production process? Read our knowledge articles.
Read our articles
Precise en Consistent Syringe Assembly
At GTE Engineering, quality, consistency, and reliability are at the core of every syringe assembly solution we design. Our syringe assembly machines can be equipped with advanced vision systems and process monitoring technologies to ensure the highest standards of product quality throughout the assembly process.
These inspection systems can verify the correct presence and positioning of syringe components, detect assembly errors, inspect labels, verify print quality, and confirm the correct orientation of products before they proceed to the next production stage. For plunger rod assembly applications, additional process controls can monitor assembly parameters to ensure consistent and accurate insertion and tightening results.
We typically integrate high-performance vision systems from leading suppliers such as Cognex to provide reliable inspection and traceability. However, if your organization has standardized on another vision platform, we can seamlessly integrate your preferred solution. This flexibility enables customers to maintain existing validation standards while benefiting from a machine tailored to their specific process requirements.
For pharmaceutical and medical device manufacturing environments, GTE Engineering also provides comprehensive validation and qualification support. This can include User Requirement Specification (URS) support, GMP-compliant documentation, and complete Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) documentation. By combining advanced inspection technology with a structured qualification approach, we help ensure that syringe assembly processes are fully compliant, reproducible, and ready for validation in regulated production environments.
Our customers
Tailored to your needs
At GTE, we understand that every production process is its own beast. That’s why our solutions are scalable and expandable at a later stage. Whereas a semi-automated solution is often chosen for a clinical trial or start-up, a fully automated solution is usually the best option for an existing production line. All our solutions can be expanded at a later stage with any additional automation measures.
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Knowledge & Inspiration
EcoVadis Silver rating
We are proud to announce that GTE Engineering has been awarded the EcoVadis Silver rating. This recognition confirms our commitment to sustainability, ethics, labour rights and responsible procurement. It is an important milestone that demonstrates our operations are structured, transparent and focused on continuous improvement.
Whitepaper: Everything about vision systems in the pharmaceutical and medical industry
Precision and accuracy are extremely important. Whether they are used for correctly labeling products, or verifying the integrity of packaging, vision systems play a crucial role in any production process. What are their strengths and limitations, how do you prepare for their implementation, and what will the future look like in terms of, for example, AI? We are happy to help you get started; download the free whitepaper!
The Importance of IQ, PQ, and OQ in Machine Construction for the Pharmaceutical and Medical Industry
In the pharmaceutical and medical industries, developing machines that meet the highest quality and regulatory standards is essential. Therefore, the steps of IQ (Installation Qualification), PQ (Performance Qualification), and OQ (Operational Qualification) are followed during the construction of these machines. These qualification tests ensure that machines meet the required standards for installation, operation, and performance, and they are a critical part of the validation process.
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