Automatic Powder Filling Bunging Machine

Q: What is the production capacity and filling accuracy of the machine?

Single Head: Up to 100 vials/minute Double Head: Up to 200 vials/minute (depending on model and vial size) Fill volume typically ranges from 50 mg to 10 grams per dose. Filling accuracy is generally ±1–3% , depending on powder bulk density uniformity and machine configuration.

Q: What are the key features of the Automatic Powder Filling Bunging Machine?

Compact cGMP-compliant monobloc design with SS316L contact parts (removable for sterilization). “No Vial – No Fill” and “No Bung – Machine Stop” systems. Integrated vibratory bung feeding and pressing unit. Variable AC frequency drive, safety clutch, and tool-less changeover. Options for PLC/HMI, inbuilt Laminar Air Flow (Class 100), and IQ/OQ documentation.

Description

Automatic Powder Filling Bunging Machine also known as an Injectable Dry Powder Filling and Stoppering Machine is a specialized automated equipment primarily used in the pharmaceutical industry for the precise filling of sterile dry powders into vials or bottles, followed by the application of rubber stoppers. This machine ensures high accuracy, sterility, and efficiency, reducing manual labor and contamination risks. It is compact, GMP-compliant, and often integrated into aseptic production lines with features like laminar airflow and isolators. These machines are essential for handling micro-doses of powders with uniform density, achieving volumetric accuracy of ±1-2%, and supporting both half and full bunging for various vial sizes. While primarily pharmaceutical, similar auger-based variants are used in food, cosmetics, and chemical sectors for filling powders like spices, proteins, or chemicals.

Drive Assembly: Consist motor, transmission and the switching mechanism to start and stop machine.

Hopper: It stored the material as a quarantine before filling. Through tooling it discharge material onto filling station.

Tooling: Tooling section consists auger agitator, funnels and other filling components to finetune the machine depending on the type of material being filled.

Structure Body: This is basic structure that supports the entire system.

Controls: This is the main mechanism to operate the machine parameters.

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Salient Features of Automatic Powder Filling Bunging Machine

“No Bottle – No Fill” System.
Standard as well as Optional Servo Driven Filling Head.
Multiple auger head system as per customer requirements.
IQ/OQ documentation can be provided.
Machine construction in SS304 material.
A.C. Variable Frequency Drive Speed Control

Filling Accuracy of +/- 3% depending upon powder characteristics and environmental conditions.
Built in Turn Tables with Separate Drive for speed control.
All contact parts made of SS316 and Nylon/HDPE material with easy removal system for Cleaning.
PLC system with Graphical User Interface can be offered.
Inbuilt Laminar Air Flow can be offered for sterile class 100 filling.

Working Principle of Automatic Powder Filling Bunging Machine

Duly cleaned containers are placed to the filling machine platform. From there containers transport towards the filling station with the help of conveyor belt. As soon as the bottle is sensed by bottle sensor, magnetic clutch starts to rotate which is mounted on the auger shaft. It fills the desired volume of powder to the container through Auger. After completion of filling process bottle transfers on conveyor for next capping operations.

The machine operates in a continuous, automated cycle under laminar flow to maintain sterility. Here’s how it typically works:

Vial Feeding: Sterile vials enter via a turntable or conveyor from a washing/tunnel system and are positioned on a star wheel or indexing plate.

Powder Dosing: Powder from a hopper is agitated and fed into a secondary hopper via vacuum. An auger screw or powder wheel rotates to measure and dispense the exact volume into each vial. Servo systems ensure repeatability.

Bunging/Stoppering: Filled vials move to the stoppering station, where rubber bungs are picked and pressed using pneumatic or mechanical presses. The system checks for proper placement.

Ejection & Inspection: Vials are ejected onto an output conveyor. Optional check-weighers or vision systems verify fill levels and seals.

Safety Halt: If a vial is missing or misaligned, sensors trigger an immediate stop to prevent waste or errors.

The entire process is controlled by PLC for seamless operation, with minimal human intervention.

Technical Specification of Automatic Powder Filling Bunging Machine

Models	AI-APF 1	AI-APF 2	AI-APF 3
Production Output	Up to 30 bottles/minute	Up to 60 bottles/minute	Up to 90 bottles/minute
Fill Volume	5gms. to 60gms. in Single Dose System	5gms. to 60gms. in Single Dose System	5gms. to 60gms. in Single Dose System
Container Size	Custom made as per required container size	Custom made as per required container size	Custom made as per required container size
Filling Accuracy	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Powder	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Powder	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Powder
Power Load	2 H. P.	3 H. P.	4.5 H. P.
Overall Dimension	1810 mm (L) x 905 mm (W) x 1900 mm approx.	2300 mm (L) x 905 mm (W) x 1900 mm approx.	3000 mm (L) x 905 mm (W) x 1900 mm approx.
Conveyor Height	850 – 950 mm adjustable	850 – 950 mm adjustable	850 – 950 mm adjustable
Electrical	415VAC 3Phase and 220 VAC Single Phase Power Supply (50 Hz) with A.C. Drive	415VAC 3Phase and 220 VAC Single Phase Power Supply (50 Hz) with A.C. Drive	415VAC 3Phase and 220 VAC Single Phase Power Supply (50 Hz) with A.C. Drive

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.

Types of Powder Filling Machines

Antibiotic Powder Filling Machine

Injectable Powder Filling Machine

Auger Powder Filling Machine

Bottle Dry Injectable Filling Machine

Automatic Dry Syrup Powder Filling Machine

Dry Syrup Powder Filler Capper

Dry Syrup Powder Filling Machine

Double Head Auger Powder Filling Machine

Applications of Powder Filling Machines

Benefits of Automatic Powder Filling Bunging Machine

Efficiency: High-speed output with low downtime; quick format changes.

Accuracy & Safety: Ensures precise dosing to meet regulatory standards; reduces powder dust and cross-contamination.

Cost-Effective: Compact size saves space; stainless steel construction ensures longevity and easy validation.

Key Features of Automatic Powder Filling Bunging Machine

Automatic powder filling bunging machines are designed for reliability and ease of use. Here are the main features based on standard models:

FeatureDescription: Compact DesignBuilt on a sturdy frame with minimal footprint; includes turntables, slat conveyor belts, and access doors for easy servicing.

Precision Filling Mechanism: Uses a powder wheel or auger with adjustable pistons or screws for exact dosing; supports multidose filling without part changes.

Bunging/Stoppering Unit: Integrated rubber stopper applicator for full/half insertion; handles dry/wet stoppers; individual drives for filling and sealing to synchronize speeds.

Safety & Automation: No-vial/no-stopper detection; digital counters for production tracking; PLC/HMI touch screens for easy setup; compatible with 21 CFR, RABS, and isolators.

FAQ for Automatic Powder Filling Bunging Machine

What is an Automatic Powder Filling Bunging Machine and how does it work?

An Automatic Powder Filling Bunging Machine is a monobloc aseptic system that fills sterile dry powders into glass vials and immediately places (bungs) partial or full rubber stoppers. It uses a vacuum-assisted powder wheel or auger mechanism for precise dosing. Filled vials are then indexed to the bunging station where siliconized rubber bungs are fed from a vibratory bowl and pressed securely. This integrated process minimizes exposure time and maintains sterility.

What is the production capacity and filling accuracy of the machine?

Single Head: Up to 100 vials/minute
Double Head: Up to 200 vials/minute (depending on model and vial size)

Fill volume typically ranges from 50 mg to 10 grams per dose. Filling accuracy is generally ±1–3%, depending on powder bulk density uniformity and machine configuration.

What types of products and containers can it handle?

It is designed for sterile injectable dry powders such as antibiotics, vaccines, and other parenteral formulations in the Pharmaceutical and Biotech industries. The machine handles standard glass vials from 5 ml to 250 ml (commonly 5–30 ml) with 13 mm or 20 mm neck sizes under controlled cleanroom conditions with laminar airflow.

What are the key features of the Automatic Powder Filling Bunging Machine?

Compact cGMP-compliant monobloc design with SS316L contact parts (removable for sterilization).
“No Vial – No Fill” and “No Bung – Machine Stop” systems.
Integrated vibratory bung feeding and pressing unit.
Variable AC frequency drive, safety clutch, and tool-less changeover.
Options for PLC/HMI, inbuilt Laminar Air Flow (Class 100), and IQ/OQ documentation.

What are the main advantages of using an Automatic Powder Filling Bunging Machine?

Superior sterility through immediate bunging after filling in a single compact unit.
High precision dosing with minimal product wastage.
Saves space in the sterile area and reduces laminar flow requirements.
Hygienic design with easy cleaning, fast changeover, and low maintenance.
High-speed automation and full regulatory compliance (cGMP/FDA) for efficient production.

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