The Guanshengtai Antigen Reagent Automated Filling and Capping Production Line is an integrated production line designed for fully automated filling and capping of in vitro diagnostic (IVD) antigen
The Guanshengtai Antigen Reagent Automated Filling and Capping Production Line is an integrated production line designed for fully automated filling and capping of in vitro diagnostic (IVD) antigen detection reagents, antibody detection reagents, and various immunochromatographic buffer solutions. The production line integrates automatic bottle feeding/dispensing, multi-channel precision liquid filling, automatic capping, servo capping, online visual inspection, automatic rejection, and bottle dispensing. The entire line achieves fully automated production from bulk empty bottles to finished reagent bottles, with a filling speed of 2400-4800 bottles/hour (depending on the number of channels and specifications), meeting the needs of large-scale standardized production of IVD reagents.
Technical parameters:
Model Number: GST-SJGZ100A
Sizes: L3800*W1400*H1800mm
Production Capacities: 300pcs/min
Power (Output): 0.75KW
Reagent Tube Capacity:0.2-20ml
Customized Support: Yes
Core Advantages:
Multi-channel Parallel Filling: 2-8 filling channels can be configured to operate in parallel according to capacity requirements. Each channel is independently controlled and operates synchronously, effectively improving unit output efficiency. Excellent consistency in filling volume between channels and good batch-to-batch repeatability.
High-precision micro-volume filling: Employing a high-precision ceramic or peristaltic pump metering system, filling accuracy is consistently within ±0.5%, with a minimum filling volume of 20μL. This is particularly suitable for high-precision quantitative dispensing of precious reagents such as antigen detection buffer solutions, avoiding reagent waste.
Drip-proof and contamination-proof: Equipped with a back-suction drip-proof filling nozzle, it automatically aspirates residual liquid from the tube immediately after filling, eliminating liquid residue at the bottle mouth and drip contamination. Each filling channel has independent tubing to avoid cross-contamination.
Intelligent capping and servo capping: Utilizing a vibratory feeder for automatic cap feeding and a vacuum cap removal mechanism, the cap is precisely placed at the bottle mouth. The servo capping system features torque closed-loop control, allowing for precise setting and real-time monitoring of the capping torque to ensure consistent sealing for each bottle, preventing slippage, misaligned caps, and over-tightening.
Online Visual Inspection: Integrates multiple visual inspection modules (based on photoelectric sensing and image comparison principles, not AI self-learning) to automatically detect filling level, cap misalignment, bottle appearance defects, and sealing tightness. Defective products are automatically rejected by air blowing and collected separately.
Cleanroom Design: The entire line uses a SUS304 stainless steel frame and transparent protective cover. The filling area meets the requirements of a Class 100,000 cleanroom environment and can be operated in an IVD cleanroom, satisfying medical device GMP and ISO13485 quality management system standards.
Rapid Changeover System: By changing the bottle type track mold, filling nozzle, and capping chuck, it can quickly adapt to different sizes of reagent bottles (1.5ml, 2ml, 3ml, 5ml, 10ml, etc.) and cap types, with changeover time controlled within 30 minutes.
Data Recording and Traceability: A built-in production data statistics system records the total number of fills, the number of qualified products, the number of defective products, and the distribution of defect types in real time. Data can be exported to a USB drive or uploaded to the MES system, meeting the traceability requirements for IVD reagent production quality management.
Easy Operation: Utilizes a PLC and touchscreen human-machine interface. Parameters for each workstation are centrally set, and multiple product formulas are built-in for one-click switching during production changes. Real-time monitoring of operating status and fault alarms with code prompts and handling guidance are provided.
Applicable Scenarios: Widely applicable to large-scale, standardized liquid filling and capping production in the in vitro diagnostics (IVD) industry (COVID-19 antigen test reagent buffer, early pregnancy test reagent, infectious disease test reagent, drug test reagent, food safety test reagent) and biopharmaceutical fields (antibody preservation solution, enzyme reaction solution, diluent). Guanshengtai's automated antigen reagent filling and capping production line, with its efficient, precise, and clean automation performance, helps IVD manufacturers achieve comprehensive automation upgrades in reagent filling and capping processes, meeting the growing capacity and quality requirements of the global market for testing reagents.
