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Challenges

  • Bubble entrainment

    Existing equipment left visible micro-bubbles in high-viscosity gels, driving unacceptable scrap rates.

  • Dosing inconsistency

    Fill-volume variation across batches failed to meet dose uniformity expectations for high-end clinical applications.

  • Aseptic vulnerability

    ​Repeated manual intervention created contamination pathways that increasingly conflicted with revised GMP sterile requirements.

  • Leading Chinese Aesthetic Brand — PFS Vacuum Filling Line for HA Serums
Leading Chinese Aesthetic Brand — PFS Vacuum Filling Line for HA Serums

Client Profile

A leading Chinese medical aesthetics biomaterials manufacturer specializing in premium cross-linked sodium hyaluronate dermal fillers. Due to the high value of these products, the filling process requires effective micro-bubble control, molecular integrity protection, and strict aseptic management, with zero tolerance for dose deviation.
Leggenda (Shanghai) Technology Co., Ltd.

Leggenda Solution

Leggenda delivered a turnkey filling line covering the complete sequence from de-bagging through filled-syringe return to nest and discharge.
Automatic de-bagger → De-lid & De-liner → Fully-servo pick-and-place station → 5-head vacuum filling & stoppering → Filled nest conveyed out

Results

  • Production Capacity
    ~4,500 syringes/hour
  • Filling Quality Improvement
    88% → >99.5% acceptance rate

  • Line productivity: Increased by approximately 30% versus legacy filling operation

  • Regulatory: Successfully passed NMPA on-site inspection; the line now operates as the client's main production line for the product.

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