Just Do It: How Syntegon Is Taking New Paths in Development

Fully automated sterile filling without human intervention—something that was long only possible for small batch sizes—has now been transferred to high-speed production by Syntegon. To achieve this, the technology provider for the pharmaceutical, biotechnology, and food industries relied on an exploratory development approach as well as formats such as the Packaging Valley Makeathon.

Syntegon’s new machine platform was developed in response to increasingly stringent regulatory requirements. Good Manufacturing Practice (GMP) guidelines stipulate that humans, as the greatest potential source of contamination, should be removed from the production process as completely as possible.

However, fully automated production also creates new challenges. What happens if an injection vial tips over or rubber stoppers stick together and block production? In the past, employees could intervene through glove ports—but this is exactly what future production processes aim to avoid.

“Suitable solutions already existed, but until now they only worked for very small volumes,” says Dr. Johannes Rauschnabel, Head of Pharma Excellence at Syntegon. “We have now brought the technology to a level that enables high-speed production.” A demonstrator of the platform was showcased at interpack 2026 and attracted significant interest.

Behind the technology lies not only a technical transformation but also a different development approach. “Our exploratory way of working was a decisive factor in the development process,” explains Rauschnabel. “It enabled us to quickly find solutions to emerging problems and led to the development of many new patents.”

While traditional engineering development processes often follow a waterfall model with strictly defined project phases, Syntegon increasingly relies on rapid testing and iterative approaches. Ideas are implemented quickly, evaluated, and either discarded or further developed as needed. This mindset is also reflected in an initiative that Rauschnabel helped launch in 2020: the Packaging Valley Makeathon.

The Makeathon brings together companies from the packaging industry and tech-savvy young talents who develop solutions to real-world challenges within two days. The format provides space for hands-on innovation and encourages unconventional approaches.

“The Makeathon is the ‘make’ version of a hackathon. Participants actually build something,” says Rauschnabel. “This allows us to tackle current engineering challenges and have ideas pre-evaluated.”

In 2025, Syntegon focused specifically on troubleshooting in fully automated sterile filling. Teams worked on solutions for issues such as tipped-over vials and stuck rubber stoppers. The advantages of the open approach quickly became apparent.

“Participants approach these problems without preconceived notions and even revisit techniques that we abandoned years ago because human intervention through glove ports was still possible back then.”

One team, for example, developed a sieve-like filtering system that allows individual stoppers to pass through while sorting out those that are stuck together. Approaches like these are directly incorporated into Syntegon’s ongoing development efforts.

The event also allows the company to position itself as an innovative industry player and connect with potential future employees. Several former participants have since joined the Syntegon team.

For Tobias Seiler, for example, the Makeathon became his gateway into the industry. Today, he works as an Automation Engineer at Syntegon. Before joining the company, he participated in the first three Makeathons and, in 2025, coached a team for the first time.

“The appeal of the Makeathon lies in building something tangible. University education is often very theoretical, whereas here you work on real industrial challenges,” he says.

The experience had a lasting impact on him both professionally and personally. “You learn to analyze quickly, rethink your approach, and find creative solutions.” He considers working with real hardware especially valuable: “After spending two intensive days working with sensors or camera technology, you develop a completely different level of understanding.”

The format also influenced his career path: “Without the Makeathon, I probably would never have discovered Syntegon. But through the event, I realized that we were an excellent fit both professionally and personally.” After working as a student trainee and completing his thesis with the company, he joined Syntegon full-time last year and now works in software development.

The Makeathon is a prime example of how Syntegon develops new technologies: openly, quickly, and with a strong practical focus. Both companies and participants benefit from direct exchange and from viewing complex challenges through different perspectives. Or, as Johannes Rauschnabel puts it: “Just do it and test a prototype quickly.”