1ml to 25ml Ampoule Filling Machine

Q: Which ampoule sizes can the 1ml to 25ml Ampoule Filling Machine handle?

The machine is specially designed to process ampoules from 1ml to 25ml (and up to 30ml in some models). It supports standard open mouth ampoules as well as onion skin ampoules. The filling range is flexible from 0.5ml to 25ml , making it highly suitable for small-volume to medium-volume sterile injectable formulations such as vaccines, antibiotics, and other parenteral drugs.

Description

1ml to 25ml Ampoule Filling Machine is a precision-engineered device designed for filling and sealing glass ampoules in pharmaceutical, biotech, cosmetic, and chemical industries. Below is a detailed description based on standard features and functionality of such machines: The machine is used for filling and sealing open-mouth or closed glass ampoules with liquid volumes ranging from 0.5ml to 25ml in a single dose. It ensures sterile, accurate, and contamination-free packaging of products like injectable drugs, veterinary medicines, agro-insecticides, cosmetics, and other chemicals.

PLC-HMI control panel for automated fill volume adjustments and real-time monitoring.
Optional laminar airflow system for Class 100 sterile filling.
Flow meters for precise regulation of oxygen, LPG, and nitrogen.
Minimal changeover time for different ampoule sizes (1ml to 25ml) with tool-free format parts.
Optional open-RABS or Class 100 laminar flow hood for enhanced sterility.
Available in single-head, two-head, four-head, or eight-head configurations for varying production needs.
Can handle Type B, C, or D ampoules with minimal changeover.
Optional integration with upstream (washing, sterilization) and downstream (inspection, labeling) equipment.

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 1ml to 25ml Ampoule Filling Machine

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

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.
Ampoule neck centering during gas flushing and filling operations.
Possibility of nitrogen gas flushing before, during and after filling.
Minimum change over time, little maintenance, easy cleaning.

Working Principle of 1ml to 25ml 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.

Technical Specification of 1ml to 25ml Ampoule Filling Machine

Model	AFS-1	AFS-2	AFS-4	AFS-8
No. of Head	Single	Two	Four	Eight
Syringes	One	Double	Four	Eight
Ampoule Sizes	1 ml to 30 ml	1 ml to 30 ml	1 ml to 20 ml	1 ml to 20 ml
Filling Speed	Up to 25 ampoules/minute	Up to 50 ampoules/minute	Up to 100 ampoules/minute	Up to 200 ampoules/minute
Filling Precision	± 1%	± 1%	± 1%	± 1%
Filling Pump	Piston Pump	Piston Pump	Piston Pump	Piston Pump
Burner Gas	LPG & Oxygen (O₂)	LPG & Oxygen (O₂)	LPG & Oxygen (O₂)	LPG & Oxygen (O₂)
Nitrogen Arrangement	Before & After Filling	Before & After Filling	Before & After Filling	Before & After Filling
Number of Fill Nozzles	One	Two	Four	Eight
Number of Nitrogen Nozzles	Two	Four	Eight	Sixteen
Number of Sealing Burners	Two	Four	Eight	Sixteen
Power Required	0.5 H.P.	1 H.P.	1 H.P.	2 H.P.
Power Voltage	230 Volts, Single Phase, 50 Hertz, 4 Wire System	230 Volts, Single Phase, 50 Hertz, 4 Wire System	230 Volts, Single Phase, 50 Hertz, 4 Wire System	230 Volts, Single Phase, 50 Hertz, 4 Wire System
Contact Parts	Made from Stainless Steel 316L	Made from Stainless Steel 316L	Made from Stainless Steel 316L	Made from Stainless Steel 316L
Overall Dimension	915mm (L) x 610mm (W) x 965mm (H) approx.	915mm (L) x 760mm (W) x 965mm (H) approx.	1200mm (L) x 1070mm (W) x 965mm (H) approx.	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 1ml to 25ml Ampoule Filling Machine

High precision and minimal product wastage.

Fast changeover for different ampoule sizes.

Robust, hygienic design for long-term use.

Protects sensitive liquids from environmental contaminants.

Scalable for small-scale labs to high-speed production lines.

Key Features of 1ml to 25ml Ampoule Filling Machine

Capacity and Flexibility:
- Suitable for filling ampoules from 1ml to 25ml (some models extend to 30ml).
- Filling capacity of 0.5ml to 25ml in a single dose, adjustable via volumetric piston pumps, peristaltic pumps, or servo-driven systems.
- Production output ranges from 10 to 300 ampoules per minute, depending on the model (e.g., single-head to eight-head machines).

Design and Construction:
- Built on a sturdy stainless steel (SS) square pipe frame, typically with AISI SS 316L contact parts and AISI SS 304 non-contact parts, complying with cGMP standards.
- Monobloc design integrates filling and sealing on a single platform for efficiency.
- Slant travel principle accommodates variations in ampoule neck dimensions, thickness, and ovality.
- Large bottom openings for easy cleaning and maintenance.
- Compact footprint with optional castor wheels for mobility.

Filling Mechanism:
- Operates on volumetric piston-pump or peristaltic pump principles for precise dosing.
- “No Ampoule, No Filling” system prevents wastage by halting filling if no ampoule is detected.
- Nitrogen flushing (pre- and post-filling) ensures inert gas protection to prevent oxidation of sensitive liquids.

Sealing Process:
- Equipped with pre-warming and sealing stations using oxygen and LPG (propane) flames.
- Pre-warming station uses low-pressure flames to prepare ampoules for sealing.
- Specially designed rollers rotate ampoules during sealing for uniform, defect-free closure.
- Waste ampoule tips are collected in a separate stainless steel container.

Operation Workflow:
- Loading: Empty, sterilized ampoules are loaded into a hopper and fed into a traveling rack (1, 2, 4, or 8 at a time, depending on the machine’s head configuration).
- Nitrogen Purging: Inert gas is flushed to remove air from ampoules.
- Filling: Filling needles dispense the preset liquid volume.
- Post-Nitrogen Flushing: Additional nitrogen is flushed to protect the liquid.
- Sealing: Ampoules are pre-warmed, sealed, and rotated for perfect sealing.
- Collection: Filled and sealed ampoules are collected upright in a dead tray for further processing.

Technical Specifications:
- Output: 25–300 ampoules/min (e.g., 290/min for 1ml, 150/min for 10ml).
- Power Supply: Single-phase or adjustable per local voltage requirements.
- Filling Accuracy: ≤±1% (depending on liquid characteristics).
- Dimensions: Approx. 2380mm (L) x 1200mm (W) x 1000mm (H) for compact models.
- Sealing Gases: Oxygen and LPG (or hydrogen/oxygen in some models).

Safety and Compliance:
- Safety valves and pressure reducers for gas circuits.
- Stainless steel hood to channel fumes during heating.
- CE certifications and IQ/OQ documentation available.
- Designed to meet GMP and pharmacopoeia standards.

Limitations:
- Primarily designed for glass ampoules; plastic ampoules require different machines.

- High-speed models (e.g., eight-head) may be cost-prohibitive for small-scale operations.
- Requires trained operators for setup and maintenance.

FAQ for 1ml to 25ml Ampoule Filling Machine

What is a 1ml to 25ml Ampoule Filling Machine?

A 1ml to 25ml Ampoule Filling Machine is a versatile, fully automatic monobloc machine designed for filling and flame sealing sterile liquid injectables into glass ampoules ranging from 1ml to 25ml. It integrates nitrogen flushing (pre- and post-filling), precise volumetric piston filling, neck pre-heating, and LPG + Oxygen flame sealing in one compact unit. This machine is widely used in pharmaceutical injectable production and complies with cGMP, USFDA, WHO, and international standards.

What is the production capacity of the 1ml to 25ml Ampoule Filling Machine?

The machine is available in multiple head configurations with the following capacities:

Single Head: Up to 25 ampoules per minute (~1,500 per hour)
Two Heads: Up to 50 ampoules per minute
Four Heads: Up to 100 ampoules per minute (~6,000 per hour)
Eight Heads: Up to 200 ampoules per minute (~12,000 per hour)

Custom high-speed models can reach up to 36,000 ampoules per hour. It handles filling volumes from 0.5ml to 25ml with ±1% filling accuracy.

Which ampoule sizes can the 1ml to 25ml Ampoule Filling Machine handle?

The machine is specially designed to process ampoules from 1ml to 25ml (and up to 30ml in some models). It supports standard open mouth ampoules as well as onion skin ampoules. The filling range is flexible from 0.5ml to 25ml, making it highly suitable for small-volume to medium-volume sterile injectable formulations such as vaccines, antibiotics, and other parenteral drugs.

What are the key features of the 1ml to 25ml Ampoule Filling Machine?

Key features include:

Wide filling range from 0.5ml to 25ml with ±1% accuracy
Nitrogen flushing before, during, and after filling
Precision piston pumps and neck centering system
Slant traveling principle for gentle handling and reduced breakage
Tool-less quick changeover with minimal parts
All product contact parts made of SS 316L
Pre-heating station and precise flame sealing
“No Ampoule – No Fill/Seal” safety system
Compact monobloc design with easy cleaning and validation

What are the main benefits of the 1ml to 25ml Ampoule Filling Machine?

Main benefits include:

Versatile filling range suitable for multiple product volumes (1ml–25ml)
High filling accuracy with minimal product wastage
Gentle handling reduces glass breakage and contamination risk
Fast format changeover for different ampoule sizes and volumes
Excellent sterility assurance through nitrogen flushing and automation
Compact footprint ideal for cleanroom environments
Full cGMP compliance and easy integration into complete injectable lines

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