Vial Powder Filling and Capping Machine

Q: What is a Vial Powder Filling and Capping Machine?

A Vial Powder Filling and Capping Machine is a fully automatic monobloc system designed for aseptic filling of sterile dry powder (such as injectable-grade antibiotics or biotech powders) into glass vials, followed by rubber stoppering and aluminum flip-off or tear-off capping in one compact unit. It operates under Laminar Air Flow (Class 100) to maintain sterility and is widely used in pharmaceutical, biotech, and injectable production lines.

Q: What is the filling accuracy and capacity of the machine?

The machine delivers a filling accuracy of ±2% (depending on powder characteristics and bulk density). It supports a fill range from 50 mg to 10 grams per vial. Available models include: - APF 12S — up to 100 vials per minute - APF 12D — up to 200 vials per minute Output varies based on vial size (5 ml to 250 ml), fill volume, and powder properties.

Q: Which vial sizes and powder types can the machine handle?

The machine is suitable for 5 ml to 250 ml glass vials (with quick changeover using minimum change parts). It handles a wide range of sterile injectable powders, including antibiotics, oncology drugs, and biotech formulations. Contact parts are made of SS316L for easy sterilization and compatibility with autoclaving.

Q: How does the Vial Powder Filling and Capping Machine ensure sterility and product safety?

Sterility is maintained through: - Operation under Laminar Air Flow (optional inbuilt Class 100) - 'No Vial – No Fill' system - Vacuum-assisted powder dosing with immediate rubber stoppering - SS316L contact parts that can be easily removed and sterilized - Optional nitrogen flushing and sampling/rejection system These features minimize contamination risk and ensure compliance with cGMP, USFDA, and WHO guidelines.

Q: What are the key features and optional accessories available?

Key features include: - Compact GMP design with servo motors for powder wheel and vial movement - Tool-less adjustment of doctor blade and wiper blade - Built-in turntables with separate drives - Safety clutch to prevent vial breakage - IQ/OQ documentation Optional accessories : PLC with HMI, inbuilt laminar airflow, multiple dosing system, and integration with vial washing, sterilization, and labeling lines for a complete injectable production setup.

Description

Vial Powder Filling and Capping Machine (also known as Injectable Powder Filling and Rubber Stoppering Machine with Cap Sealing Machine) is a high-precision pharmaceutical packaging machine designed for aseptic filling of dry powder (injectable grade) into glass vials, followed by rubber stoppering and aluminum flip-off or tear-off cap sealing — all in a single compact monobloc unit under laminar airflow (LAF). It performs three critical operations in a single compact unit: powder filling, rubber stoppering, and aluminum flip-off or tear-off capping.

This advanced injectable powder filling machine is ideal for pharmaceutical and biotech companies producing antibiotic powders, oncology drugs, vaccines, and other sterile powder formulations. The entire process occurs under Laminar Air Flow (Class 100) to ensure maximum sterility and minimal risk of contamination, making it fully compliant with cGMP, USFDA, and WHO guidelines.

Salient Features of Vial Powder Filling and Capping Machine

Compact GMP Model.
Filling Accuracy of ± 2% depending upon powder characteristics and environmental conditions.
Powder wheel rotation and vial transportation through servo motors.
Various safety features including Clutch system for Vial Breakage.
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.
Sampling and Rejection system can be provided on demand.

Suitable to fill 50mg to 10 grams.
Built in Turn Tables with Separate Drive for speed control of infeed and outfeed of vials.
Vacuum driven specially designed Powder Wheels.
Built in Rubber Stoppering System.
IQ/OQ 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.
Multiple dosing system with the help of change parts.

Working Principle of Vial Powder Filling and Capping 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 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 Vial Powder Filling and Capping Machine

Models	APF 12S	APF 12D
Production Output	Up to 100 vials/minute	Up to 200 vials/minute
Fill Volume	50 mg. to 10 grams	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 and Capping Machine

High Production Speed and Output

Superior Filling Accuracy and Uniformity

Three-in-One Monoblock Operation

Enhanced Sterility and Contamination Control

Minimal Product Wastage and Cost Savings

Easy Integration, Flexibility, and Regulatory Compliance

Key Components of Vial Powder Filling and Capping Machine

Operation Principle: Auger-based servo-driven powder filling system with “No Vial – No Fill” logic, vacuum-assisted powder dosing wheel, and pick-and-place type rubber stoppering & cap sealing.

Capacity Range: 20 to 300 vials/min (depending on model: 50–100–150–200–240–300 vials/min).

Filling Accuracy: ±1% (depending on powder bulk density and vial neck diameter).

Vial Range: 5 ml to 100 ml glass vials.

Powder Type: Sterile antibiotic, oncology, biotech, and injectable powders.

Stopper & Cap: 13 mm, 20 mm, 28 mm, 32 mm butyl rubber stoppers & flip-off/tear-off aluminum seals.

FAQ for Vial Powder Filling and Capping Machine

What is a Vial Powder Filling and Capping Machine?

A Vial Powder Filling and Capping Machine is a fully automatic monobloc system designed for aseptic filling of sterile dry powder (such as injectable-grade antibiotics or biotech powders) into glass vials, followed by rubber stoppering and aluminum flip-off or tear-off capping in one compact unit. It operates under Laminar Air Flow (Class 100) to maintain sterility and is widely used in pharmaceutical, biotech, and injectable production lines.

What is the filling accuracy and capacity of the machine?

The machine delivers a filling accuracy of ±2% (depending on powder characteristics and bulk density). It supports a fill range from 50 mg to 10 grams per vial.
Available models include:
– APF 12S — up to 100 vials per minute
– APF 12D — up to 200 vials per minute

Output varies based on vial size (5 ml to 250 ml), fill volume, and powder properties.

Which vial sizes and powder types can the machine handle?

The machine is suitable for 5 ml to 250 ml glass vials (with quick changeover using minimum change parts). It handles a wide range of sterile injectable powders, including antibiotics, oncology drugs, and biotech formulations. Contact parts are made of SS316L for easy sterilization and compatibility with autoclaving.

How does the Vial Powder Filling and Capping Machine ensure sterility and product safety?

Sterility is maintained through:
– Operation under Laminar Air Flow (optional inbuilt Class 100)
– “No Vial – No Fill” system
– Vacuum-assisted powder dosing with immediate rubber stoppering
– SS316L contact parts that can be easily removed and sterilized
– Optional nitrogen flushing and sampling/rejection system

These features minimize contamination risk and ensure compliance with cGMP, USFDA, and WHO guidelines.

What are the key features and optional accessories available?

Key features include:
– Compact GMP design with servo motors for powder wheel and vial movement
– Tool-less adjustment of doctor blade and wiper blade
– Built-in turntables with separate drives
– Safety clutch to prevent vial breakage
– IQ/OQ documentation

Optional accessories: PLC with HMI, inbuilt laminar airflow, multiple dosing system, and integration with vial washing, sterilization, and labeling lines for a complete injectable production setup.

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