Eight Needle Ampoule Filling Machine

Q: How does the Eight Needle Ampoule Filling Machine work?

The machine operates on the slant traveling principle for gentle ampoule handling and reduced glass breakage. The automated process includes: Automatic loading of sterilized ampoules from the hopper Nitrogen pre-flushing to remove oxygen Simultaneous filling through eight needles with neck centering Nitrogen post-flushing Neck pre-warming Accurate flame sealing using LPG + Oxygen burners It is equipped with “No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems to prevent wastage and ensure maximum sterility.

Description

Eight Needle Ampoule Filling Machine is a high-speed, advanced piece of pharmaceutical equipment designed for precise Filling and Sealing of glass ampoules, primarily used in sterile pharmaceutical, biotech, cosmetic, veterinary, and chemical industries. Below is a detailed description based on industry standards and available information:

Safety cabinet with doors and Class 100 laminar airflow for sterile filling.

Compatibility with both open-mouth and closed-mouth (Type B and C) ampoules.

Dead tray for upright collection of filled ampoules and waste tip collector for easy disposal.

CE and ISO 9001:2000 certifications for quality assurance.

This machine ensures compliance with cGMP standards for sterile injectable filling. If you need details on specific models, pricing, or comparisons with multi-head machines, let me know!

Salient Features of Eight Needle Ampoule Filling Machine

Compact cGMP model.
Higher output up to 12000 Ampoules per hour.
Full accessibility allows easy maintenance.
Flow Meters for regulating flames easily.
“No Ampoule – No Filling” system.
Machine equipped with pre-warming station.

Ampoule neck centering during gas flushing and filling operations.
Possibility of nitrogen gas flushing before, during and after filling.
All contact parts made from High Quality Stainless Steel 316L & Non-contact parts made from Stainless Steel 304.
Minimum change over parts from 1ml to 10ml ampoule size.
Minimum change over time, little maintenance, easy cleaning.

Working Principle of Eight Needle Ampoule Filling Machine

Empty washed & sterilized ampoules loaded onto infeed hopper of the machine. From where it has been received to receiving rack through starwheel/cassette. The moving rack which moves horizontally collect eight ampoules from the receiving rack and transfer the ampoule to the machine in left to right in an inclined position. During ampoule movement Pre-gassing, Filling, Post Gassing, Pre-heating & Sealing Station perform Filling and Sealing Operations. At the end duly filled and sealed ampoules get collected automatically onto collection tray of the machine.

Sterilized ampoules are loaded into the slant hopper.

A synchronized star wheel delivers ampoules (in groups of eight) to a moving eccentric rack.

Ampoules move through stations for:
- Pre-Nitrogen Flushing: Inert gas to maintain sterility.
- Filling: Precise liquid dosing via chosen pump mechanism.
- Post-Nitrogen Flushing: Additional gas flush to prevent contamination.
- Preheating: Warms ampoule necks for sealing.
- Sealing: Uses LPG/oxygen for a clean, secure seal.

Filled and sealed ampoules are automatically collected in an upright position on a tray, with waste tips ejected into a separate container.

Technical Specification of Eight Needle Ampoule Filling Machine

Model Name	AFS-8
Production Speed	Up to 200 ampules/minute
Ampoule Sizes	1 ml to 20 ml
Filling Error	± 1%
Sealing Gas	LPG and Oxygen (O₂)
Nitrogen Gas	Pre & Post Nitrogen
Power Load	2 H. P.
Power Voltage	230 Volts, Single Phase, 50 Hertz
Contact Parts	Made from Stainless Steel 316L
Non-Contact Parts	Made from Stainless Steel 304
Machine Size	2200mm (L) x 1400mm (W) x 1100mm (H) 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 Ampoule Filling Machine

Automatic Ampoule Filling Sealing Machine

Laboratory Ampoule Filling Sealing Machine

Closed Ampoule Filling Machine

Open Mouth Ampoule Filling Machine

Onion Skin Ampoule Filling Machine

Single Head Ampoule Filling Machine

Double Head Ampoule Filling Machine

Four Head Ampoule Filling Machine

Six Head Ampoule Filling Machine

Eight Head Ampoule Filling Machine

Applications of Ampoule Filling Machine

Advantages of Eight Needle Ampoule Filling Machine

High Precision: Minimal breakage and accurate dosing for high reliability.

Low Maintenance: Quick-change parts and easy cleaning reduce operational costs.

Versatility: Handles a wide range of ampoule sizes and liquid types with customizable filling options.

Sterility: Nitrogen flushing and GMP-compliant materials ensure product safety.

Global Reach: Machines are exported to over 48 countries.

Key Features of Eight Needle Ampoule Filling Machine

High-Speed Production:
- Capable of filling and sealing up to 12,000 ampoules per hour (approximately 80–280 ampoules per minute, depending on ampoule size and liquid viscosity). For example, it can process up to 290 ampoules/min for 1ml ampoules, 270 for 2ml, 260 for 3ml, 240 for 5ml, and 150 for 10ml.
- Ideal for medium to large-scale production lines requiring high output with minimal errors.

Filling and Sealing Mechanism:
- Filling Capacity: Handles ampoule sizes from 0.5ml to 25ml in a single dose, with precise volume control. Common models support 1ml to 10ml ampoules, with some offering flexibility up to 20ml.
- Filling Options: Equipped with multiple filling mechanisms, including:
  1. Piston Pump Filling: Ensures consistent dosing for various liquids.
  2. Servo-Driven Filling: Enhances accuracy with programmable control.
  3. Peristaltic Pump Filling: Ideal for sterile operations, minimizing contamination.
- Two-Stage Sealing Process:
  1. Preheating: Removes residual droplets to ensure clean sealing.
  2. Sealing: Uses LPG and oxygen with clippers for precise, defect-free seals.
- Nitrogen Flushing: Pre- and post-filling nitrogen purging to maintain sterility and prevent contamination.

Construction and Compliance:
- Built on a stainless steel square pipe frame with SS 316L contact parts for injectable liquids, ensuring compliance with cGMP standards. Non-contact parts are typically made of SS 304.
- GMP Compliance: Designed for sterility, with contact surfaces ensuring hygiene for injectable liquids.
- Robust Design: Heavy-duty stainless steel piping and anti-rust treatment for durability and jerk-free operation.
- Easy Maintenance: Features a large bottom opening for cleaning and quick-changeover parts to minimize downtime when switching ampoule sizes (1ml to 10ml).

Operational Efficiency:
- Slant Travel Mechanism: Ampoules move in an inclined position through filling and sealing stations, accommodating variations in neck dimensions and thicknesses.
- No Ampoule, No Fill System: Prevents liquid wastage by halting filling when no ampoule is detected.
- Neck Centering: Ensures precise alignment during filling, gas flushing, and sealing for improved accuracy.
- Automated Process: Sterilized ampoules are loaded into a slant hopper, delivered via a synchronized star wheel to an eccentric rack, and processed through pre-gassing, filling, post-gassing, preheating, and sealing stations. Filled ampoules are collected automatically without manual handling.

Advanced Features:
- PLC-Based Control: Some models include a PLC with an HMI touch screen for automatic fill volume adjustments, reducing manual intervention.
- Servo-Based Vertical Models: High-speed vertical fillers with 8, 12, or 16 nozzles for enhanced precision.
- Pre-Warming Unit: Ensures proper heating of ampoule necks for flawless sealing, especially for thicker glass.
- Gas Flow Meters: Acrylic body meters for easy flame setting (oxygen and LPG).

FAQ for Eight Needle Ampoule Filling Machine

What is an Eight Needle Ampoule Filling Machine?

An Eight Needle Ampoule Filling Machine (also known as Eight Head Ampoule Filler Sealer) is a high-speed, fully automatic monobloc machine designed for filling and flame sealing sterile liquid injectables into glass ampoules. It uses eight filling needles working simultaneously and integrates nitrogen flushing (pre- and post-filling), precise volumetric piston filling, neck pre-heating, and LPG + Oxygen flame sealing in one compact unit. This model is ideal for large-scale pharmaceutical production and complies with cGMP, USFDA, WHO, and international regulatory standards.

What is the production capacity of the Eight Needle Ampoule Filling Machine?

The Eight Needle Ampoule Filling Machine (Model AFS-8) has a production capacity of up to 200 ampoules per minute (approximately 12,000 ampoules per hour). It supports ampoule sizes from 1ml to 20ml with a filling range of 0.5ml to 25ml and maintains excellent filling accuracy of ±1%. Higher custom models can reach up to 36,000 ampoules per hour.

How does the Eight Needle Ampoule Filling Machine work?

The machine operates on the slant traveling principle for gentle ampoule handling and reduced glass breakage. The automated process includes:

Automatic loading of sterilized ampoules from the hopper
Nitrogen pre-flushing to remove oxygen
Simultaneous filling through eight needles with neck centering
Nitrogen post-flushing
Neck pre-warming
Accurate flame sealing using LPG + Oxygen burners

It is equipped with “No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems to prevent wastage and ensure maximum sterility.

What are the key features of the Eight Needle Ampoule Filling Machine?

Key features include:

Eight needle / eight head monobloc design for maximum productivity
Nitrogen flushing before, during, and after filling
Precision piston pumps for accurate dosing
Tool-less quick changeover with minimal parts
All product contact parts made of SS 316L
Slant design for smooth movement and low glass particle generation
Pre-heating station and precise flame control with flow meters
Compact footprint with easy cleaning and maintenance
Optional PLC/HMI with SCADA compatibility

What are the main benefits of the Eight Needle Ampoule Filling Machine?

Main benefits include:

Very high production speed of up to 200 ampoules per minute (~12,000 per hour)
Excellent filling accuracy (±1%) with minimal product wastage
Gentle handling that reduces glass breakage and contamination risk
Ideal for large-scale and high-volume injectable production
Fast format changeover and easy validation
Compact design suitable for cleanroom environments
Full cGMP compliance and reliable high-performance operation

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