Dry Injection Filling Sealing Machine

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 50 mg to 10 grams (with multiple dosing options). Filling accuracy is ±2% to ±3% , depending on powder bulk density uniformity and controlled environmental conditions.

Description

Dry Injection Filling Sealing Machine is a specialized pharmaceutical machine designed for the aseptic filling of sterile dry powder into vials or ampoules, followed by sealing to ensure product integrity. These machines are critical for producing moisture-sensitive injectables that require reconstitution before use, ensuring precision, sterility, and compliance with cGMP, FDA, and EU standards.

Dry Injection Filling Sealing Machine operates as a monobloc system for streamlined, contamination-free processing:

Vial Infeed: Sterile vials are fed via a conveyor, turntable, or unscrambler into the filling station.

Powder Filling: Servo-driven or vacuum-pressure systems dispense precise powder doses using augers, pistons, or dosing wheels. Accuracy is ±1-2%, adjustable for powder density.

Stoppering: Rubber stoppers are placed using a pick-and-place mechanism, often under laminar airflow or in an isolator to ensure sterility.

Sealing: Aluminum caps are crimped or pressed onto vials for an airtight seal. Some machines integrate capping stations.

Output: Sealed vials are discharged for inspection, labeling, or packaging.

Advanced models may include pre-cleaning with Water for Injection (WFI), sterilization tunnels, and integration with checkweighers or vision systems for quality assurance.

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

Salient Features of Dry Injection Filling Sealing Machine

Compact GMP Model.
“No Vial, No Filling” system eliminates wastage of costly powder.
All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.
High Volumetric Filling Accuracy of ±2% of uniform density Injectable powder can be ensured by setting the depth of piston in the port of powder wheel.
Built-in Rubber Stoppering Unit saves lot of space in the Sterile Area & reduces the length of Laminar Flow.

Individual drive for the filling & sealing to match the speed of filling & sealing.
Multiple Dosing System.
Safety clutch system to avoid Vial breakage.
Variable AC Frequency Drive for speed adjustment.
All contact parts are easily removable for mandatory Autoclaving/ Sterilization.
Digital counter for counting production output.

Working Principle of Dry Injection Filling Sealing Machine

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 eight ports rotates at the 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 in to 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. (Different grooves separator can be used which depends on the container diameter or multiple dosing systems). 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 the container is passed between two pressing roller for tight fit fixing of rubber stopper.

Technical Specification of Dry Injection Filling Sealing Machine

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

Benefits of Dry Injection Filling Sealing Machine

High Accuracy: Ensures consistent dosing, reducing product waste.

Aseptic Operation: Minimizes contamination risks through enclosed systems and minimal human intervention.

Versatility: Supports various vial sizes, powder types, and sealing methods (stoppers or caps).

Efficiency: High-speed production with low maintenance; suitable for small to large-scale operations.

Key Features of Dry Injection Filling Sealing Machine

Compact cGMP Monobloc Design

Space-saving GMP-compliant unit that integrates filling, stoppering, and sealing in one machine. Minimizes Laminar Air Flow length and reduces sterile area footprint.

“No Vial – No Fill” System

Advanced sensor-based system ensures filling occurs only when a vial is present, eliminating wastage of costly sterile powder.

Vacuum-Driven Powder Wheel with Piston

High-precision volumetric filling using vacuum suction and adjustable piston depth. Supports single and multiple dosing for fill volumes from 50 mg to 10 grams.

Built-in Rubber Stoppering & Sealing Unit

Integrated vibrating bowl for stopper feeding and precise pneumatic/mechanical insertion, followed by aluminum cap crimping/sealing for airtight closure.

High Filling Accuracy

Achieves ±2% to ±3% accuracy depending on powder bulk density uniformity. Doctor blade and wiper blade are adjustable without removing the hopper.

Safety & Protection Features
- Safety clutch system to prevent vial breakage
- Overload protection for motors with contractors and relays
- Machine stop on empty stopper chute

Individual Drives & Variable Speed Control

Separate drives for filling and sealing operations with Variable AC Frequency Drive for precise synchronization and speed adjustment (up to 100–200 vials per minute).

Easy Cleaning & Sterilization

All product contact parts are SS316L and easily removable for autoclaving/sterilization. Tool-less adjustments simplify maintenance.

Advanced Controls & Options

Digital production counter, optional PLC with HMI, Inbuilt Laminar Air Flow (Class 100), nitrogen flushing, and IQ/OQ documentation support.

Robust Construction & Integration

Sturdy, vibration-free design suitable for vial sizes from 5ml to 250ml. Seamless integration into complete vial packaging lines (filling → stoppering → sealing → labeling).

FAQ for Dry Injection Filling Sealing Machine

What is a Dry Injection Filling Sealing Machine and how does it work?

A Dry Injection Filling Sealing Machine is a monobloc aseptic system that fills sterile dry powder into vials, inserts rubber stoppers, and then seals the vials with aluminum caps in one continuous operation. It uses a vacuum-driven powder wheel with pistons: powder is agitated in the hopper, sucked into the wheel ports via vacuum, excess is doctored off, and flushed into vials. Filled vials are immediately stoppered and crimped/sealed to maintain sterility. This integrated design minimizes contamination risks in sterile areas.

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 50 mg to 10 grams (with multiple dosing options). Filling accuracy is ±2% to ±3%, depending on powder bulk density uniformity and controlled environmental conditions.

What types of vials and powders can it handle?

It is designed for sterile dry powder injectables (antibiotics, vaccines, and moisture-sensitive formulations) in the pharmaceutical and biotech industries. Compatible vial sizes range from 5ml to 250ml. The vacuum powder wheel system handles powders with varying flow properties effectively. All product contact parts are SS316L for easy sterilization and full cGMP compliance.

What are the key features of the Dry Injection Filling Sealing Machine?

Compact cGMP monobloc design with vacuum powder wheel and built-in stoppering + sealing
“No Vial – No Fill” system to eliminate wastage
Multiple dosing system with adjustable piston depth
Safety clutch system to prevent vial breakage
Individual drives with Variable AC Frequency Drive for synchronized filling and sealing
All SS316L contact parts easily removable for autoclaving and tool-less adjustments
Digital production counter, optional PLC/HMI, Laminar Air Flow (Class 100), and IQ/OQ documentation

These features ensure high sterility, precision, and efficiency.

Why is integrated sealing important and what maintenance does the machine require?

Integrated stoppering and sealing immediately after filling protects moisture-sensitive powders, maintains sterility, and ensures airtight closure for longer shelf life. The machine is fully cGMP-compliant. Maintenance is straightforward: all contact parts are easily removable for autoclaving/sterilization. Regular procedures include cleaning the powder wheel, hopper, agitators, doctor blade, stoppering, and sealing components while maintaining controlled cleanroom temperature and humidity.

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