5ml Ampoule Filling Machine

Description

5ml Ampoule Filling Machine is a specialized piece of equipment designed for filling and sealing 5ml glass ampoules, commonly used in pharmaceutical, biotech, cosmetic, veterinary, and chemical industries. Below is a detailed description of a typical 5ml Ampoule Filling Machine based on current industry standards and available technology:

Sterilized 5ml ampoules are loaded into a slant hopper or infeed conveyor.

A star wheel transfers ampoules to a transport rack in groups (1/2/4/8, depending on the number of heads).

Ampoules undergo pre-nitrogen flushing, filling with the precise 5ml volume, and post-nitrogen flushing.

Pre-warming prepares the ampoule neck for sealing, followed by flame sealing using oxygen and LPG.

Sealed ampoules are collected on a tray or outfeed conveyor, while waste tips are ejected separately.

Production Needs: Choose the number of heads based on required output (e.g., four-head for medium-scale, eight-head for large-scale).

Filling Mechanism: Peristaltic pumps are ideal for sterile applications, while piston pumps suit viscous liquids.

Sterility Requirements: Opt for models with LAF or isolator systems for aseptic filling.

Customization: Ensure the machine supports 5ml ampoules with minimal changeover time.

Supports ampoule sizes from 1ml to 30ml with minimal changeover parts, making it versatile for 5ml ampoules.

Can be integrated with upstream (e.g., washing, sterilizing tunnels) and downstream (e.g., inspection, labeling) equipment for a complete production line.

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 5ml Ampoule Filling Machine

Compact model.
All contact parts made from high quality Stainless Steel 316 & other Non-contact parts made from Stainless Steel 304.
“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.
Minimum change over time, little maintenance & easy cleaning.

Working Principle of 5ml Ampoule Filling Machine

Closed mouth/pre 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 one/two/four/eight ampoules from the receiving rack and transfer the ampoule to the machine in left to right in an inclined position. During ampoule movement sequentially below operations performed:

Pre-gassing with Nitrogen
Filling the product
Post Gassing with Nitrogen
Pre-heating with LPG & Oxygen combination
Sealing with LPG & Oxygen combination

At the end duly filled and sealed ampoules get collected automatically onto collection tray of the machine. Ampoules now can be collected for further inspection and/or sticker labeling operations.

Technical Specification of 5ml 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 Precison	± 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 Arranegment	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 5ml Ampoule Filling Machine

High-speed production with minimal human intervention, reducing labor costs and contamination risks.

Compact monoblock design combines filling and sealing on a single platform, saving space.

Flexibility to handle various ampoule types (Type B, C, or D) and liquid viscosities, from free-flowing to heavy oils.

Easy maintenance and quick changeover for different ampoule sizes, enhancing operational efficiency.

Key Features of 5ml Ampoule Filling Machine

Purpose and Application:
- Designed to fill and seal 5ml open-mouth or closed-mouth glass ampoules with liquid or semi-liquid products, such as injectable drugs, serums, or chemicals.
- Ensures sterile, precise, and high-speed filling to meet Good Manufacturing Practices (cGMP) standards for pharmaceutical production.

Filling Capacity and Accuracy:
- Suitable for filling volumes ranging from 0.5ml to 5ml in a single dose, with some models adjustable up to 25ml.
- High fill accuracy of ±0.5% to ±1%, depending on the filling mechanism (e.g., piston pump, peristaltic pump, or servo-driven systems).

Construction and Materials:
- Built with a stainless steel (SS 316L) frame and contact parts to ensure durability, corrosion resistance, and compliance with cGMP standards.
- Non-contact parts are typically made of SS 304, with a matte finish for easy cleaning and maintenance.
- Features a large bottom opening for thorough cleaning and accessibility.

Filling and Sealing Process:
- Filling: Utilizes volumetric piston pumps, peristaltic pumps, or servo-driven systems for precise dosing. Co-eccentric nozzles ensure quick and accurate filling without spillage.
- Nitrogen Flushing: Includes pre- and post-nitrogen flushing stations to minimize contamination and ensure sterility by displacing oxygen.
- Sealing: Employs oxygen and LPG (propane) flames for sealing, with pre-warming and sealing stations to ensure perfect closure. Specially designed rollers rotate ampoules for uniform sealing.
- Slant Travel Principle: Ampoules move at an angle during filling and sealing to accommodate variations in neck dimensions, thickness, and ovality.

Production Capacity:
- Output varies by model:
  - Single-head machines: ~15–40 ampoules per minute (900–2,400 per hour).
  - Two-head machines: ~40–100 ampoules per minute (2,400–6,000 per hour).
  - Four-head machines: ~80–150 ampoules per minute (4,800–9,000 per hour).
  - Six- or eight-head machines: Up to 200–300 ampoules per minute (12,000–18,000 per hour).
- For 5ml ampoules, typical output for a four-head machine is around 100–150 ampoules per minute, depending on liquid viscosity and machine configuration.

Automation and Control:
- Equipped with PLC (Programmable Logic Controller) and HMI (Human-Machine Interface) for automated fill volume adjustments and real-time monitoring.
- Features like “No Ampoule, No Fill” and “No Ampoule, Machine Stop” prevent wastage and ensure operational safety.
- Servo-driven models allow precise control of filling volume via touch-screen interfaces.

Additional Features:
- Infeed and Outfeed: Ampoules are loaded via a hopper or infeed conveyor, moved through a star wheel to a transport rack, and collected in a dead tray or outfeed conveyor after sealing.
- Pre-Warming Station: Ensures thick glass ampoules are adequately heated for sealing without cracking.
- Waste Tip Collection: Sealed ampoules are separated from waste tips, which are collected in a separate container.
- Laminar Air Flow (LAF): Optional for sterile class 100 filling to maintain aseptic conditions.
- Safety Features: Includes safety clutches, pressure reducers, and stainless steel hoods to channel fumes during sealing.

Power and Dimensions:
- Typical power requirements: 1–2 H.P., 230–380V, single or three-phase, 50 Hz (customizable per regional voltage standards).
- Dimensions vary by model but are compact, e.g., ~915mm (L) x 760mm (W) x 965mm (H) for a two-head machine, up to ~2380mm (L) x 1200mm (W) x 1000mm (H) for larger models.

FAQ for 5ml Ampoule Filling Machine

What is a 5ml Ampoule Filling Machine and what does it do?

The 5ml Ampoule Filling Machine is a compact, automatic monoblock system designed to fill and seal pre-sterilized 5ml glass ampoules with liquid or semi-liquid injectable products such as vaccines, antibiotics, serums, or chemicals. It performs nitrogen flushing (before and after filling), precise volumetric piston filling, neck pre-heating, and flame sealing in a single operation. This ensures high sterility, minimal contamination risk, and compliance with cGMP standards for pharmaceutical and biotech production.

What is the production capacity (output) of the 5ml Ampoule Filling Machine?

Our 5ml Ampoule Filling Machine is available in different models with varying outputs:

Single-head (AFS-1): Up to 25 ampoules per minute (~1,500/hour)
Two-head (AFS-2): Up to 50 ampoules per minute (~3,000/hour)
Four-head (AFS-4): Up to 100 ampoules per minute (~6,000/hour)
Eight-head (AFS-8): Up to 200 ampoules per minute (~12,000/hour)

The exact speed for 5ml ampoules depends on liquid viscosity and ampoule type. All models deliver consistent ±1% filling accuracy using high-precision piston pumps.

What ampoule sizes can the machine handle, and how easy is changeover?

The machine is optimized for 5ml ampoules but supports a wide range from 1ml to 30ml (up to 20ml on multi-head models). It handles open-mouth or closed-mouth ampoules (Type B, C, or D). Changeover between sizes is quick and tool-less with minimal parts replacement, reducing downtime significantly. A “No Ampoule – No Filling” system prevents wastage during operation.

How does the machine maintain product sterility and quality?

Sterility is maintained through:

Pre- and post-filling nitrogen flushing to remove oxygen and prevent oxidation.
Ampoule neck centering during flushing and filling.
Pre-warming station before flame sealing with LPG + Oxygen.
All product contact parts made of Stainless Steel 316L.
Optional Laminar Air Flow (LAF) for Class 100 aseptic conditions.

The slant travel principle ensures gentle handling to minimize glass breakage. The machine complies with USFDA and WHO guidelines for sterile injectable filling.

What are the power requirements and key safety features?

The machine requires low power: 0.5 HP to 2 HP (depending on the model) at 230 Volts, Single Phase, 50 Hz (customizable as per your country’s voltage). Key safety and operational features include safety clutches, pressure reducers, stainless steel hoods for fume extraction, full accessibility for cleaning, and easy maintenance. It integrates seamlessly with upstream (washing/sterilizing) and downstream (inspection/labeling) equipment for a complete production line.

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