1、 The core challenge of filling high viscosity liquid pre filled syringes

Filling high viscosity liquid medicine (such as viscosity)>At 100cP, the efficiency of conventional equipment drops sharply, facing multiple technical bottlenecks:

·Difficulty in defoamingLiquids are prone to carry bubbles and difficult to release naturally;

·High flow resistanceDuring the transportation process, there are many residues and high losses;

·Restricted sterile filtrationHigh viscosity leads to a decrease in membrane flux and is prone to clogging;

·Low filling accuracyUnstable fluid control affects dose accuracy;

·Add a plug to introduce bubblesMechanical action disturbs the liquid level, increasing the risk of bubble formation.

Especially when the viscosity exceeds5000cP (such as hyaluronic acid products) requires specialized processes and equipment to ensure production quality.

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2、 Vacuum filling: a key technological path for dealing with high viscosity liquids

Traditional positive pressure filling is prone to turbulence and bubble entrapment, whileVacuum filling technologyBy creating a controllable negative pressure environment（0 – 50kPa adjustable), which can be filled smoothly by using the vacuum adsorption principle to effectively avoid the formation of foam.

The advantages of this plan include:

·Liquid is automatically drawn into the needle under negative pressure, reducing shear force;

·cooperate, coordinate, collaborateClass 100 laminar flow hoodEnsure sterile transmission;

·The vacuum filling and vacuum plugging system are independently controlled to improve sealing reliability.

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3、 Key structural design and fluid management optimization

To improve conveying efficiency and filling stability, the system adopts the following customized components:

·Liquid storage and distribution system：316L stainless steel material, no corner design, reduces residue;

·measuring deviceHigh precision ceramic plunger pump（± 1% error), suitable for high viscosity fluids;

·Filling needle componentEquipped with overload alarm and anti splash structure, coordinated withPEEK vacuum chamber sleeve, supporting complex viscosity conditions;

·Full private server control：Highly stable jobEnsure the success rate of congestion>99%.