Vial Powder Filling Machine

Q: How does the Vial Powder Filling Machine ensure filling accuracy and sterility?

Filling accuracy is typically ±2% (or ±2–3% depending on powder bulk density and uniformity). Sterility is maintained through: “No Vial – No Filling” system to prevent wastage and contamination. Easily removable contact parts for autoclaving/sterilization (SS 316 compatible). Operation under Laminar Air Flow (Class 100) with optional inbuilt LAF. Built-in rubber stoppering unit that reduces laminar flow area. Options for integration under isolators or RABS. All product contact parts are designed for easy cleaning and sterilization, meeting strict USFDA and cGMP guidelines.

Q: What are the power requirements and key features of the Vial Powder Filling Machine?

Power requirements are model-specific: APF 12S : 3.5 HP APF 12D : 4.5 HP (Power voltage can be customized as per your country’s requirements.) Key features include: Safety clutch system to avoid vial breakage Variable AC frequency drive for speed control Digital production counter Individual drives for filling and stoppering Agitated powder hopper with vacuum-pressure dosing Optional servo motors, PLC + HMI, multiple dosing, and in-process weight checking The compact cGMP model integrates seamlessly with vial washing, sterilizing, capping, and labeling machines for a complete production line.

Description

Vial Powder Filling Machine (also known as an Injectable Powder Filling Machine or Sterile Powder Filler) is a specialized piece of pharmaceutical equipment designed for the precise, automated filling of sterile dry powders into glass vials. These machines are essential in the production of injectable medications, such as antibiotics, vaccines, and lyophilized drugs, ensuring sterility, accuracy, and compliance with Good Manufacturing Practices (GMP) and FDA standards. They operate in aseptic environments to minimize contamination risks and are often integrated into complete vial processing lines that include washing, sterilization, stoppering, capping, and labeling.

Vial Preparation: Empty sterile glass vials enter via infeed turntable after upstream washing and depyrogenation (using hot air ovens or tunnels).

Powder Filling: Vials are positioned under the powder wheel. Vacuum/pressure draws and dispenses a precise powder dose into each vial. Agitators ensure consistent flow.

Stoppering: A vibrating feeder drops rubber stoppers, which are pressed into place.

Outfeed and Integration: Filled and stoppered vials exit to capping/sealing stations. The entire line can achieve up to 19,200 vials per hour in high-speed models.

Inspection: Inline checks for fill weight, stopper placement, and defects.

Salient Features of Vial Powder Filling Machine

Compact cGMP model.
“No Vial, No Filling” system eliminates wastage of costly powder.
Individual drive for the filling & sealing to match the speed of filling & sealing.
Safety clutch system to avoid Vial breakage.
Variable AC Frequency Drive for speed adjustment.
Digital counter for counting production output.

Multiple Dosing System.
Built-in Rubber Stoppering Unit saves lot of space in the Sterile Area & reduces the length of Laminar Flow.
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.
All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.
All contact parts are easily removable for mandatory Autoclaving/ Sterilization.

Working Principle of Vial Powder Filling 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 Vial Powder Filling 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 Vial Filling Machine

Automatic Vial Filling Machine

High Speed Vial Filling Machine

Vial Liquid Filling Machine

Vial Powder Filling Machine

Automatic Vial Filling and Rubber Stoppering Machine

Lab Scale Vial Filling Stoppering & Cap Sealing Machine

Injectable Vial Powder Filling & Stoppering Machine

Peristaltic Pump based Vial Filling Machine

Applications of Vial Filling Machine

Benefits of Vial Powder Filling Machine

Industries: Primarily pharmaceuticals, biotech, and cosmetics for sterile powders like cephalosporins or lyophilized biologics.

Production Speeds: Ranges from 30–200 vials per minute (VPM) in compact GMP models to 300+ VPM in automated lines.

Advantages: High precision reduces waste, minimizes human intervention for sterility, and supports scalability. Compact designs fit under containment systems, and servo technology ensures repeatability.

Key Components of Vial Powder Filling Machine

Powder Dosing System: Utilizes vacuum-driven powder wheels or servo-controlled pistons for volumetric filling. Powder is stored in a hopper agitated by mechanical stirrers to maintain uniform density. Dosing ranges from 50mg to 1500mg per vial, with options for multiple doses via changeable parts.

Filling Accuracy: Typically ±2% (or better, up to ±0.05% in advanced servo models), depending on powder characteristics, humidity, and environmental conditions.

Stoppering Mechanism: Built-in rubber bunging or stoppering system inserts sterile stoppers immediately after filling to preserve integrity.

Turntables and Conveyor: Infeed and outfeed turntables with independent drives for smooth vial handling and speed control. Vials are transported via a synchronized conveyor or indexing system.

Safety and Controls: Includes clutch systems for vial breakage prevention, tool-less blade adjustments, PLC interfaces with graphical user interfaces (GUI), and optional in-process weight checking or rejection systems. Many models support IQ/OQ validation documentation.

Sterility Enhancements: Options for inbuilt laminar airflow (Class 100), autoclavable SS316 contact parts, and integration under isolators or RABS (Restricted Access Barrier Systems).

Customization: Servo motors for powder wheel rotation and vial transport; adaptable for different vial sizes . Advanced models allow split-filling of multiple powders in one vial with 100% check-weighing.

FAQ for Vial Powder Filling Machine

What is a Vial Powder Filling Machine and what does it do?

The Vial Powder Filling Machine is a fully automatic system designed to precisely fill sterile dry powders into glass vials for injectable medications such as antibiotics, vaccines, and lyophilized drugs. It uses a vacuum-pressure powder wheel system with an agitated hopper and doctor blade for accurate dosing, followed by rubber stoppering. The machine operates in aseptic conditions with a built-in stoppering unit, ensuring high sterility, minimal contamination, and compliance with cGMP and FDA standards. It is ideal for pharmaceutical and biotech production lines.

What is the production capacity of the Vial Powder Filling Machine?

Our Vial Powder Filling Machine is available in two main models:

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

Actual output depends on vial size, powder characteristics, and fill volume. The machine supports high-speed production lines with outputs up to 19,200 vials per hour when integrated with upstream and downstream equipment.

Which vial sizes and fill volumes can the Vial Powder Filling Machine handle?

The machine handles a wide range of vial sizes from 5ml to 250ml. It can fill powder doses from 50 mg to 10 grams per vial. Changeover between different vial sizes is straightforward with minimum change parts. The versatile design makes it suitable for both small-batch and large-scale sterile powder filling in pharmaceutical production.

How does the Vial Powder Filling Machine ensure filling accuracy and sterility?

Filling accuracy is typically ±2% (or ±2–3% depending on powder bulk density and uniformity). Sterility is maintained through:

“No Vial – No Filling” system to prevent wastage and contamination.
Easily removable contact parts for autoclaving/sterilization (SS 316 compatible).
Operation under Laminar Air Flow (Class 100) with optional inbuilt LAF.
Built-in rubber stoppering unit that reduces laminar flow area.
Options for integration under isolators or RABS.

All product contact parts are designed for easy cleaning and sterilization, meeting strict USFDA and cGMP guidelines.

What are the power requirements and key features of the Vial Powder Filling Machine?

Power requirements are model-specific:

APF 12S: 3.5 HP
APF 12D: 4.5 HP

(Power voltage can be customized as per your country’s requirements.)

Key features include:

Safety clutch system to avoid vial breakage
Variable AC frequency drive for speed control
Digital production counter
Individual drives for filling and stoppering
Agitated powder hopper with vacuum-pressure dosing
Optional servo motors, PLC + HMI, multiple dosing, and in-process weight checking

The compact cGMP model integrates seamlessly with vial washing, sterilizing, capping, and labeling machines for a complete production line.

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Vial Powder Filling Machine

Description

Salient Features of Vial Powder Filling Machine

Working Principle of Vial Powder Filling Machine

Technical Specification of Vial Powder Filling Machine

Types of Vial Filling Machine

Applications of Vial Filling Machine

Benefits of Vial Powder Filling Machine

Industries: Primarily pharmaceuticals, biotech, and cosmetics for sterile powders like cephalosporins or lyophilized biologics.

Production Speeds: Ranges from 30–200 vials per minute (VPM) in compact GMP models to 300+ VPM in automated lines.

Advantages: High precision reduces waste, minimizes human intervention for sterility, and supports scalability. Compact designs fit under containment systems, and servo technology ensures repeatability.

Key Components of Vial Powder Filling Machine

FAQ for Vial Powder Filling Machine

Countries We Export to

Partner with Industry Experts

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