ASSEMBLING WHAT MATTERS
Syringe assembly.
Every variant.
Plunger rod, backstop or finger flange, label and tray, each step in its own module. Add a needle safety device when your syringe needs one.
15–30
parts per minute, depending on configuration
< 15
minutes to change between syringe variants
UP TO
ISO 7
cleanroom-ready modules
Full
traceability per device
WITH ROCHE
“At Roche, we were looking for a modular, flexible solution for assembling different devices and found this solution in ESSERT’s MicroFactory Ecosystem.”
Philip Schneider
Drug Product Manufacturing Network Technology Lead, Roche
2025
ISPE Robotics Application of the Year Award for the MicroFactory Assembly Line, together with Roche.
Best Innovative Technical Concept and Audience Award.
Your syringe changes.
Your line doesn’t.
Conventional syringe assembly lines are built for one product. When the syringe changes, you face long changeovers and assets that sit idle, and every new process step means a costly revalidation.
CONVENTIONAL LINE
New variant
Manual format adjustments, the line stands still.
CONVENTIONAL LINE
New step
A new component, a safety device for example, means rebuilding the line.
CONVENTIONAL LINE
Revalidation
Every new process step puts the whole line back into validation.
CONVENTIONAL LINE
Next product
Built for one syringe, idle when the portfolio shifts.
From syringe to tray.
One module per step.
ASSEMBLY
Syringe feeding › Plunger rod › Backstop or finger flange
Each process runs in its own module:
Syringe feeding from tub or Rondo tray
Plunger rod assembly
Finger flange assembly
Backstop assembly
Safety device assembly
LABELING AND TRAY LOADING
Labeling › Tray loading
Labeled and loaded, one module per step:
Syringe labeling
Safety device labeling
Tray loading
New variant?
Same line.
< 15 min
to change between syringe variants.
A software-driven architecture minimizes manual format adjustments, so the line changes to the next syringe variant automatically.
New only
is validated when the line grows.
Each module is pre-qualified. When you add a module, you validate the new addition, while the modules that already run stay as they are.
Conventional assembly lines are built for one product. A MicroFactory line runs syringes, autoinjectors and pens. Select a recipe, and in under 15 minutes the next batch runs: another syringe type or a different device altogether.
IN ACTION · 0:47
Syringe assembly at work.
A MicroFactory Assembly Line assembling syringes, from feeding to tray.
SHOWN: MICROFACTORY ASSEMBLY LINE · SYRINGES EXAMPLE
Two configurations.
One line that grows.
Start with the configuration that fits your syringe today and add modules as your product changes.
STANDARD
5 modules
PROCESSES
Syringe feeding to tray loading
MADE FOR
Early-stage production and frequent format changes
MODULES
Pre-qualified, reusable for other products
WITH SAFETY DEVICE
7 modules
ADDED
Safety device feeding and safety device assembly
CORE PROCESS
Stays as validated
VALIDATION
The two new modules only
SHOWN: ILLUSTRATIVE CONFIGURATIONS · ACTUAL LAYOUT DEPENDS ON YOUR DEVICE
Syringe, components, batch sizes. We come back with a proposal within two working days.
Built on the MicroFactory Ecosystem.
One MicroFactory Core under every ESSERT module: standardized baseframe, interfaces, controller, safety and software. Syringe Assembly runs on it, one module per process.
SINCE 2012 · 100+ MANUFACTURERS · ISPE ROBOTICS APPLICATION OF THE YEAR AWARD, 4 YEARS IN A ROW
FAQ
Questions
we get asked.
What comes up in first calls, answered short.
The long answers we bring to the meeting.
Which steps does the line cover?
Syringe feeding, plunger rod assembly, backstop or finger flange assembly, labeling and tray loading. Modules for safety device feeding and assembly can be added.
Can we add a needle safety device later?
Yes. Modules for safety device feeding and assembly are added without altering the validated core process. Only the new modules are validated.
How long does a changeover take?
Under 15 minutes. The software-driven architecture minimizes manual format adjustments and changes the line to a new syringe variant automatically.
What batch sizes does the line handle?
Down to batch size 1. Changeovers between syringe variants are software-driven and take under 15 minutes.
Can the line run in a cleanroom?
Yes. The modules are built for GMP environments up to ISO 7.
How fast is the line installed?
Modules are fully commissioned before delivery and connect through plug-and-produce interfaces, which keeps on-site ramp-up short.
Can we start with a pre-series?
Yes. Automate your manual process with standard process modules, validate it in the pre-series and transfer it to a MicroFactory line later.
Does the same platform assemble autoinjectors?
Yes. Autoinjector assembly runs on the same MicroFactory modules.
