Single Wheel Powder Filling Machine

Description

Single Wheel Powder Filling Machine is a specialized piece of equipment primarily used in the pharmaceutical industry for accurately filling sterile dry powders into glass vials. It operates on a rotary wheel principle, where a single rotating wheel with multiple ports (typically 12) draws precise volumes of powder via vacuum suction and dispenses them into vials. This machine often integrates rubber stoppering (bunging) in a monoblock setup, ensuring cGMP compliance for sterile production. It’s designed for high accuracy and is commonly used for fill weights ranging from 50mg to 1,500mg per vial.

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Salient Features of Single Wheel Powder Filling Machine

“No Vial – No Filling” system eliminates wastage of costly powder.
Overload Relay for any overload accident.
Flexible to suit from 5 ml. to 30 ml. vials.

All Contact Parts are of S.S 316L.
Quick change over with minimum use of tools.
Contact parts are removable for mandatory autoclaving.

Working Principle of Single Wheel Powder Filling Machine

Powder Preparation: Powder is loaded into the hopper and agitated for consistency.

Vial Feeding: Empty vials are fed onto a conveyor and positioned under the rotating powder wheel.

Filling: As the wheel rotates, vacuum draws powder into each port. The filled ports align with vials, and powder is discharged by releasing vacuum and pushing via pistons.

Stoppering: Rubber stoppers are automatically placed and pressed into the vials.

Output: Filled and stoppered vials exit for further processing (e.g., capping).

Technical Specification of Single Wheel Powder Filling Machine

Model	AI-SPFM
Filling Range	50mg. To 1.5 gms. In Single Dose, 1.5 gms. To 6 gms. In Double, Triple and Four Dose system
Accuracy	± 1% depending upon consistency and uniformity of bulk density of Injectable Powder under controlled level of humidity (below 28% RH)
Humidity	Below 28% Rh required on machine to be arrange by customer
Electrical	415VAC 3Phase and 220 VAC Single Phase Power Supply (50 Hz) with A.C. Drive
Power	0. 5 H.P., 230 Volts, 1 Phase
Compressed Air	Max. 2 Kg/Cm2 Oil Free
Vacuum	25″ Hg. @ 300 LPM displacement
Conveyor Height	815-940 mm
Overall Dimensions	2800 mm (L) x 840 mm (W) x 1675 mm, Model AHPF-120
Production Output	40 fills/ min. for Single Dose, 20 fills/ min. for Double Dose, 12 fills/ min. for Triple Dose, 10 fills/ min. for Four Dose
Net Weight	250 Kgs.
Gross Weight	310 Kgs.

* 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 Single Wheel Powder Filling Machine

Compact and Cost-Effective Design

Ease of Operation and Maintenance

Versatility and Efficiency

Lower Risk and Compliance

Key Features of Single Wheel Powder Filling Machine

Compact GMP-compliant design: Fully stainless steel construction (often SS316L for contact parts) for hygiene, durability, and pharmaceutical compliance. Easy-to-clean and autoclavable parts.

Powder Wheel Mechanism: A rotating wheel (typically with 8–12 ports) with pistons, vacuum plate, and doctor blade for precise volumetric dosing. Vacuum sucks powder into ports; compressed air (or nitrogen) discharges it into vials. Adjustable piston length for different fill volumes.

High Filling Accuracy: Typically ±2% to ±3% (or better), depending on powder bulk density, flow characteristics, and environmental conditions. Suitable for fills from 50mg to 1.5g (or up to 5–10g) in single dosing.

Production Speed: Up to 100–120 vials per minute (varies by model, vial size, and powder). Single-wheel models are suited for medium output; double-wheel variants exist for higher speeds.

Integrated Rubber Stoppering: Often monobloc with built-in vibratory stopper bowl, chute, and pressing system for immediate sealing after filling. Supports half/full bunging.

Servo/PLC Controls: Servo motors for wheel rotation and vial transport; PLC with HMI/touchscreen for easy parameter adjustment (speed, dose, etc.). Features like “No Vial – No Fill.”

Turn Tables and Conveyor: Infeed/outfeed turntables with individual drives and slat conveyor for smooth, synchronized vial handling and reduced breakage.

Safety and Utility Features:
- Tool-less adjustments for doctor/wiper blades.
- Clutch system for vial breakage protection.
- Low air/vacuum machine stop.
- Optional inbuilt Laminar Air Flow (Class 100), sampling/rejection, and IQ/OQ documentation.

Versatility: Handles various vial sizes (with change parts); multiple dosing options. Designed for free-flowing to cohesive sterile powders.

FAQ for Single Wheel Powder Filling Machine

What is a Single Wheel Powder Filling Machine and how does it work?

The Single Wheel Powder Filling Machine is a high-precision, rotary volumetric filler designed for sterile dry powder filling into glass vials (typically 5ml to 30ml). It uses a single rotating powder wheel with multiple ports (usually 12). Powder is drawn into the ports by vacuum, and a piston system with compressed air/nitrogen discharges the exact dose into the vial. It is often integrated with automatic rubber stoppering in a monoblock design for cGMP-compliant injectable production.

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

The machine supports a filling range of 50mg to 1.5g in single dose, and up to 6g with double/triple/four-dose systems. Filling accuracy is ±1% (depending on powder bulk density and humidity control below 28% RH). Production output is approximately 40 vials per minute for single dose, reducing with multiple doses (e.g., 20 fills/min for double dose). Output may vary by model and vial size.

What vial sizes and types of powders can the Single Wheel Powder Filling Machine handle?

It is flexible for 5ml to 30ml glass vials with quick change-over using minimum tools and change parts. It is ideal for sterile injectable powders such as antibiotics and other free-flowing to slightly cohesive pharmaceutical powders. All product contact parts are made of SS 316L for hygiene and autoclaving.

What are the key features and safety systems of this machine?

Key features include:

“No Vial – No Fill” system to prevent powder wastage
Overload relay protection
Tool-less quick change-over
Removable contact parts for easy cleaning and autoclaving
SS 316L contact parts
Servo/PLC controls with low air/vacuum stop
Integrated turntables and conveyor for smooth vial handling

These ensure reliability, minimal downtime, and full cGMP compliance.

Why is humidity control important and what maintenance is required?

Maintaining humidity below 28% RH is critical to ensure powder flow consistency, prevent clumping, and achieve the stated filling accuracy. The machine is designed for easy maintenance — contact parts are removable for mandatory autoclaving, and most adjustments (doctor blade, wiper blade, etc.) are tool-less. Regular cleaning of the powder wheel, hopper, and sensors is recommended for optimal performance.

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