WLS Introduces PR-12 and PR-24 Plunger Rod Insertion and Labeling Systems

WLS, a ProMach product brand, introduces the PR-12 and PR-24 plunger rod insertion and labeling systems for syringes at Pack Expo Las Vegas booth W-1152. Featuring WLS’s new patent-pending Automated Torque Regulation (ATR) technology, these first-of-their-kind systems combine precise plunger rod insertion with high-speed labeling into a cost-effective, compact unit. By improving reliability and streamlining production, the PR-12 and PR-24 help pharmaceutical manufacturers and contract packers protect product quality and reduce waste while maximizing operational efficiencies.

“Our original goal was simply to consolidate insertion and labeling into a single unit, but in talking to our customers, it became clear that traditional plunger rod insertion designs weren’t up to our high standards due to issues with plunger positioning, torque control and seal integrity,” said Adam Rosenthal, Director of Sales and Marketing at WLS. “By leveraging our team’s in-house engineering expertise, we knew we could improve the process and build something significantly better. Our next-generation PR systems not only merge two operations but also introduce a smarter, more controlled way to insert plunger rods.”

WLS’s innovative ATR technology automatically adapts the torque based on individual syringes to prevent over or under rotation. Additionally, the systems compensate for plunger placement tolerance of +/- 5mm to ensure the plunger rod is accurately seated into the plunger every time without disrupting the plunger height or seal during insertion. These unique features achieve superior control to better protect the aseptic seal created by the plunger.

The PR systems are designed for liquid injectable prefilled syringes ranging from 0.5 to 5 mL and can accommodate a variety of pressure-sensitive label materials. The PR-12 runs at speeds up to 300 syringes per minute while the PR-24 reaches speeds up to 600.

Syringes enter the PR via a synchronized feedscrew and are held in place by mechanical gripper mechanisms mounted to a rotary dial during plunger rod insertion. The syringes are then passed to a second rotary dial where they are nested in vertical trunnion rollers for label application, providing accurate and repeatable label placement.

The PR systems use the same proven X5 label head and vacuum drum technology found on WLS’s popular VR-72 labeler to print, inspect and apply wrap-around labels in continuous motion. The vacuum drum label dispenser holds each syringe with three contact points during labeling to minimize label skew, while the continuous motion provides smoother tension on the label web to reduce web break and expand material options. Optional redundant label heads are available to facilitate high-speed labeling with zero downtime.

The PR-12 and PR-24 accommodate different types of code printing methods, inspection systems and reject options. They are capable of printing lot numbers, expiration dates and 2D codes, with or without serialized data. WLS’s patented label Reconciler automatically tracks and removes out-of-tolerance labels from the vacuum drum prior to application onto the syringe.

Changeover between different syringe fills or sizes is fast and tool-less, with no need to raise or lower syringe or plunger rod infeed/outfeed dials. The systems feature an 18.5-inch color touchscreen HMI with configurable linear and rotational set values. The cGMP-compliant designs meet pharmaceutical manufacturing requirements. Optional 21 CFR Part 11 compliance with Audit Trail, Domain Authentication and various types of data collection are available.

WLS offers world-class aftersales support. Its dedicated team of field technicians provides in-person installation, start-up assistance, modifications to existing equipment and emergency service to quickly speed resolution and keep customers’ systems operating at peak performance.