Ujoin Medical Technology’s COP/COC Prefilled Syringe Production and Assembly Line Officially Put into Operation

Recently, Ujoin Medical Technology’s fully automated production and assembly line for cycloolefin polymer/cycloolefin copolymer (COP/COC) prefilled syringes was officially Put into Operation. This project represents China’s first fully integrated, world-class automated production line for such products. It successfully breaks through the technical barriers to large-scale production of high-end COP/COC prefilled syringes, achieves a major upgrade in production equipment, steadily raises quality management standards, and establishes a differentiated competitive edge for the company’s manufacturing operations.

COP/COC polymeric materials, combining high transparency, low protein adsorption, high heat resistance, and excellent biocompatibility, have become the substrate of choice for premium prefilled syringes. However, these materials are highly heat-sensitive, demand tight dimensional tolerances, and require narrow processing windows, imposing extremely stringent control requirements on cleanroom grades, component assembly precision, silicone oil coating consistency, and terminal sterilization stability.

For a long time, the industry has relied on an island-style semi-automated production model with manual intervention, entailing quality risks such as particulate contamination and fluctuations in packaging compatibility, which are major technical hurdles for high-end pharmaceutical packaging manufacturing.

With years of deep expertise in the pharmaceutical packaging sector, and leveraging the drive to build a national-level smart factory, UJoin Medical Technology has focused on resolving the critical pain points in R&D and production of premium packaging materials. Through sustained efforts to overcome COP/COC mass-production challenges, backed by rich process know-how and quality management experience, the company has taken the lead in introducing world-class intelligent production lines to accelerate its smart manufacturing upgrading.

The new production line integrates five core modules—magnetic-levitation feeding, silicone spraying, intelligent vision inspection, precision marking, and flexible packaging. It can be intelligently linked with plastic injection moulders, accommodates multiple specifications of COP/COC prefilled syringe, and supports 32-cavity high-precision molds with flexible compatibility.

The line employs magnetic-levitation conveying technology for efficient, damage-free automatic alignment and feeding of syringe, and uses bottom-up atomized spraying to ensure uniform silicone oil coating with controllable dosage. Equipped with an industrial camera matrix and deep-learning algorithms, it achieves micron-level defect detection with a reject sorting accuracy of 99.98%. By applying substrate activation modification and specialized ink processes, it thoroughly resolves issues of ink smudging at room temperature and hydrolysis/heat-migration resistance after high-temperature sterilization, ensuring clear and stable marking. Meanwhile, each box carries a unique code for full traceability throughout the product lifecycle.

The entire line is optimized for quality, efficiency, labor savings, and reduced consumption: it features full-process Class A unidirectional airflow protection and ion static elimination systems to rigorously control particulate contamination; high-speed automated operations compress production time by 60%; critical process CPK values remain above 1.67; and it replaces repetitive manual tasks previously performed by 11 workers across 5 positions. With precise closed-loop control, the packaging material scrap rate has been reduced from 35% to 5%, significantly elevating production quality management and overall operational performance.

Going forward, Ujoin Medical Technology will accelerate the deployment of a full-chain digital control platform for COP/COC prefilled syringes, strengthen data interconnection across raw materials, processes, and testing, and comprehensively advance intelligent production upgrading. With a well-rounded product portfolio and world-class production quality management, the company is committed to providing safe, high-quality, and reliable domestically manufactured solutions for the global biopharmaceutical, medical aesthetic, and premium injectable pharmaceutical sectors.