2ml Ampoule Filler

2ml ampoule filler is a specialized machine designed for the precise filling and sealing of 2ml glass ampoules, commonly used in pharmaceutical, biotech, cosmetic, and chemical industries. Below is a detailed description based on current industry standards and available information:

A 2ml ampoule filler is a compact, automated or semi-automated machine engineered to fill and seal 2ml glass ampoules with liquids, such as injectable drugs, serums, or other sterile solutions. These machines ensure high accuracy, sterility, and compliance with cGMP (current Good Manufacturing Practices) standards, making them ideal for small to medium-scale production in pharmaceutical and cosmetic applications.

 Ampoule Filler Video

Key Features:

• Capacity and Output: Suitable for filling 2ml ampoules (open or closed types) with a filling range typically from 0.5ml to 2ml in a single dose. Production capacity varies by model, ranging from 1,500 to 4,500 ampoules per hour for smaller-scale machines (e.g., single or double-head fillers) to 12,000+ ampoules per hour for high-speed models (e.g., four or eight-head fillers).Filling Mechanism: Utilizes precise filling systems such as peristaltic pumps, servo-driven pumps, or piston pumps to ensure accurate dosing with minimal wastage. Some models feature a “no ampoule, no fill” function to reduce product loss.

• Sealing Process: Employs a high-precision sealing system using oxygen and LPG (propane) flames. The process includes pre-heating and sealing stations, where ampoule necks are heated, rotated by specially designed rollers for uniform sealing, and sealed airtight to ensure sterility and prevent contamination.

• Nitrogen Purging: Incorporates pre- and post-filling nitrogen flushing to displace atmospheric air, minimizing oxidation and ensuring product stability, especially for sensitive pharmaceuticals.

• Construction: Built with high-grade stainless steel (SS 316L for contact parts and SS 304 for non-contact parts) for durability, corrosion resistance, and compliance with cGMP standards. The design often includes a monobloc structure, combining filling and sealing on a single platform for efficiency.

• Operation: Features a user-friendly touchscreen interface or PLC (Programmable Logic Controller) system for easy control of filling volume, sealing temperature, and speed. Some models include automatic stop functions to prevent errors and reduce wastage.

• Ampoule Handling: Ampoules are loaded via a hopper, transferred through a starwheel or cassette to a slant-travel rack for processing. The slant-travel mechanism accommodates variations in ampoule neck dimensions and thicknesses, ensuring precise centering during filling and sealing.

• Customization: Adjustable trays and change parts allow compatibility with ampoule sizes from 1ml to 30ml, though optimized for 2ml. Options for safety cabinets, laminar airflow, or isolator systems are available for enhanced sterility.

• Maintenance and Cleaning: Designed for easy maintenance with large bottom openings for thorough cleaning. Flow meters regulate flame intensity, and efficient cooling systems prevent overheating, extending machine lifespan.

Operational Process:

1. Loading: Sterilized 2ml ampoules are loaded into the hopper and fed into a receiving rack via a starwheel or cassette.

2. Nitrogen Pre-Flushing: Nitrogen gas is flushed into the ampoules to remove atmospheric air.

3. Filling: Precise volumes (0.5ml–2ml) are dispensed into the ampoules using filling nozzles, with neck centering for accuracy.

4. Nitrogen Post-Flushing: Additional nitrogen flushing occurs post-filling to ensure product integrity.

5. Pre-Heating and Sealing: Ampoules are pre-warmed at a low-pressure flame station, then sealed at a high-precision sealing station using combustible gases. Rollers rotate ampoules for uniform sealing.

6. Collection: Filled and sealed ampoules are automatically collected in an upright position on a tray for further processing (e.g., labeling or inspection).

Applications:

• Pharmaceuticals: Filling injectable drugs, vaccines, or sterile solutions.

• Cosmetics: Filling serums or essential oils, as seen in machines like the ZONESUN ZS-FSAB2 double-head filler.

• Biotech and Chemicals: Handling agro-insecticides, veterinary medicines, or other liquid formulations.

Advantages:

• High accuracy in filling and sealing, ensuring product safety and sterility.

• Fast changeover between ampoule sizes, enhancing production flexibility.

• Compact, monobloc design saves space and simplifies operation.

• Compliance with GMP and CE standards, suitable for regulated industries.

• Low maintenance and robust construction for long-term reliability.

Considerations:

• Output Needs: Choose single or double-head fillers for small-scale production (1,500–4,500 ampoules/hour) or multi-head (four, six, or eight) for higher outputs (up to 12,000 ampoules/hour).

• Ampoule Type: Ensure the machine supports closed or open 2ml ampoules, with specific models like the ZONESUN ZS-FSAB2 optimized for closed types.

• Sterility Requirements: Opt for models with laminar airflow or isolator systems for enhanced aseptic conditions in pharmaceutical applications.

Types of Ampoule Filler

We offer below mentioned different types of ampoule filling machines:

• Laboratory Ampoule Filling Machine
• Closed 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
• Onion Skin Ampoule Filling Machine

Salient Features of  Ampoule Filler

• Compact cGMP model.

• Higher output up to 12000 Ampoules per hour.

• 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.

• “No Ampoule – No Filling” system.

• Ampoule neck centering during gas flushing and filling operations.

• Possibility of nitrogen gas flushing before, during and after filling.

• Full accessibility allows easy maintenance.

• Machine equipped with pre-warming station.

• Flow Meters for regulating flames easily.

• Minimum change over time, little maintenance, easy cleaning.

Working Principle of Ampoule Filler

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 Ampoule Filler Machine

* 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.