Dry Injection Vial Powder Filler

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

The machine is available in two models: APF 12S (Single Head) : Up to 100 vials per minute APF 12D (Double Head) : Up to 200 vials per minute Fill volume ranges from 50mg to 10 grams (up to 1500mg in single dosing, higher with multiple dosing via change parts). Filling accuracy is ±2% to ±3% , depending on powder characteristics, bulk density uniformity, and environmental conditions (e.g., controlled humidity).

Description

Dry Injection Vial Powder Filler, also known as an injectable powder filling machine or vial dry powder filling machine, is specialized equipment used in the pharmaceutical industry to precisely fill glass vials with sterile dry powder formulations for injectable medications. These powders are typically moisture-sensitive drugs that remain stable in dry form until reconstituted with a solvent before administration. Dry Injection Vial Powder Filler ensures aseptic conditions to prevent contamination, meeting strict cGMP standards.

Vial Feeding: Empty sterile vials are loaded manually or via an automatic infeed system.

Powder Dosing: A servo-driven or vacuum powder wheel dispenses exact amounts of powder into each vial. The wheel rotates precisely, often using auger or syringe mechanisms for control.

Rubber Stoppering: A built-in system partially inserts rubber plugs (stoppers) to seal the vial while allowing later needle insertion.

Quality Checks: Sensors detect under/over-fills, missing vials, or defects; rejects are automatically removed.

Outfeed: Filled and stoppered vials exit for capping, labeling, or further packaging.

The entire process is monobloc for space efficiency and reduced contamination risk.

If you need details on specific models and pricing, let me know!

Salient Features of Dry Injection Vial Powder Filler

Compact GMP Model.
Filling Accuracy of ± 2% depending upon powder characteristics and environmental conditions.
Powder wheel rotation and vial transportation through servo motors.
Vacuum driven specially designed Powder Wheels.
All contact parts made of SS316L materials with easy removal system for Autoclaving / Sterilization.
Tool Less adjustment of Doctor Blade and Wiper Blade saves valuable time and easy for setting.
Built in Turn Tables with Separate Drive for speed control of infeed and outfeed of vials, Built in Rubber Stoppering System.

Suitable to fill 50mg to 1500mg in single dosing.
Multiple dosing system with the help of change parts.
Various safety features including Clutch system for Vial Breakage.
IQ/OQ Validation documentation can be provided.
PLC system with Graphical User Interface can be offered.
Inbuilt Laminar Air Flow can be offered for sterile class 100 filling.
Sampling and Rejection system can be provided on demand.

Working Principle of Dry Injection Vial Powder Filler

The sterilized powder is stored in powder hopper is agitated by pair of mechanical agitators for maintaining consistency and uniform bulk density. The powder wheel having twelve ports which rotates at pre-determined speed below the powder hopper with practically no clearance. Powder wheel consist of Piston in each port and behind the powder wheel vacuum plate is provided. There is no clearance between powder wheel and vacuum plate due to back spring pressure. Precise volume of powder is sucked into the port of powder wheel during vacuum; according to the piston length different fill size can be achieved. The excess powder is doctored off by a doctor blade. Doctor blades can be adjusted from outside also without removing powder hopper. When powder wheel indexes further and remain in the port due to the vacuum till it reaches just vertically above the container. The time dose of Compressed air (Nitrogen Gas), sterilized low pressure air sequentially flushes out powder from the port of powder wheel in to the container one by one.

The filled containers are immediately separated on the conveyor by vial separator and moves further for stoppering operation.

The sterilized, siliconised, rubber stoppers stored in the vibrator bowl moves to vibratory bowl and stacked vertically in the rubber stopper chute. The container is hold firmly between pair or timing belt to pickup rubber stopper from exit end of the chute. Further container is passed between two pressing roller for tight fit fixing of rubber stoppers.

Technical Specification of Dry Injection Vial Powder Filler

Models	APF 12S	APF 12D
Production Output	Up to 100 vials/minute	Up to 200 vials/minute
Fill Volume	50 mg. to 10grams	50 mg. to 10 grams
Vial Size	5ml to 250ml	5ml to 250ml
Filling Accuracy	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder
Power Load	3.5 H. P.	4.5 H. P.
Overall Dimension	2600mm (L) X 1100mm (W) X 1800mm (H) approx.	3000mm (L) X 1100mm (W) X 1800mm (H) approx.
Net Weight	500 kgs. approx.	700 kgs. approx.
Gross Weight	750 kgs. approx.	950 kgs. approx.

* 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

Advantages of Dry Injection Vial Powder Filler

Excellent Filling Accuracy & Consistency

High Production Speed & Throughput

Superior Handling of Challenging Powders

cGMP Compliance & High Hygiene Standards

Improved Product Stability & Safety

Key Features of Dry Injection Vial Powder Filler

Precision Dosing: Achieves filling accuracy of ±0.5% to ±2%, depending on powder type and environmental factors, minimizing waste and ensuring dosage consistency.

Sterility: Operates in cleanroom environments with features like vacuum-driven systems to reduce airborne particles.

Efficiency: Automates filling, rubber stoppering, and sometimes capping, boosting production from 20–60 vials per minute (VPM) for single-wheel models to 100–250 VPM for double-wheel or high-speed variants.

Versatility: Handles various vial sizes and powder characteristics; compatible with multiple dosing via change parts.

FAQ for Dry Injection Vial Powder Filler

What is a Dry Injection Vial Powder Filler and how does it work?

A Dry Injection Vial Powder Filler is specialized aseptic equipment used in the pharmaceutical industry to fill sterile dry powders into glass vials for injectable medications. It uses a vacuum-driven powder wheel with pistons: sterilized powder is agitated in the hopper for uniform density, sucked into the wheel ports via vacuum, excess is doctored off, and then flushed into vials using compressed/nitrogen gas. Filled vials are immediately partially stoppered to maintain sterility. The process is monobloc for reduced contamination risk.

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

The machine is available in two models:

APF 12S (Single Head): Up to 100 vials per minute
APF 12D (Double Head): Up to 200 vials per minute

Fill volume ranges from 50mg to 10 grams (up to 1500mg in single dosing, higher with multiple dosing via change parts). Filling accuracy is ±2% to ±3%, depending on powder characteristics, bulk density uniformity, and environmental conditions (e.g., controlled humidity).

What types of vials and powders can it handle?

It is designed for sterile dry powder injectables (e.g., antibiotics and moisture-sensitive formulations) in the pharmaceutical and biotech industries. Compatible vial sizes range from 5ml to 250ml. The vacuum-driven system excels with challenging powders that have poor flow properties. All product contact parts are SS316L for easy sterilization and compliance with strict aseptic requirements.

What are the key features and benefits of the Dry Injection Vial Powder Filler?

Compact cGMP model with servo-driven systems and vacuum powder wheel
Built-in rubber stoppering system and turn tables with separate drives
Tool-less adjustment of doctor and wiper blades
Safety features like clutch system for vial breakage protection
Options: PLC with HMI, Laminar Air Flow (Class 100), “No Vial – No Fill”, IQ/OQ documentation, and sampling/rejection system

Benefits include high sterility assurance, minimal wastage, fast changeover, low maintenance, and seamless integration into complete vial lines.

Is the machine suitable for sterile pharmaceutical production and what maintenance is required?

Yes, it is fully cGMP-compliant and designed for sterile environments with SS316L contact parts that are easily removable for autoclaving/sterilization. It supports cleanroom Class 100 operation with optional inbuilt Laminar Air Flow. Maintenance is straightforward due to tool-less adjustments and robust design. Regular procedures include cleaning the powder wheel, hopper, and stoppering components while maintaining controlled temperature and humidity for optimal powder flow.

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