Ampoule Filler Sealer for Glass Ampoules

Description

Ampoule Filler Sealer for Glass Ampoules is a high-precision, compact monobloc machine designed for automatic filling and hermetic flame sealing of open-mouth glass ampoules. Built on the advanced slant travel mechanism, the machine ensures smooth handling of ampoules even with variations in neck dimensions, thickness, or ovality. It is ideal for sterile filling of injectable liquids in the pharmaceutical, biotechnology, cosmetic, veterinary, and chemical industries. This cGMP-compliant ampoule filling and sealing machine performs multiple operations in one unit: ampoule feeding, nitrogen purging (before, during, and after filling), precise volumetric filling, pre-heating, and gas-based flame sealing. Sealed ampoules are automatically collected on a dead tray, minimizing manual handling and contamination risks.

Loading: Sterilized ampoules are loaded into a slant hopper via trays or cassettes.
Transport: A star wheel or cassette transfers ampoules to a rack (single, two, four, or eight at a time) for slant travel.
Pre-Gassing: Nitrogen is flushed to remove atmospheric air.
Filling: Precise amounts of liquid or powder are dispensed using piston or peristaltic pumps.
Post-Gassing: Additional nitrogen flushing to ensure sterility.
Pre-Heating: Ampoule necks are warmed to prepare for sealing.
Sealing: Flame or laser seals the ampoule by melting the neck (tip or pull sealing).
Collection: Sealed ampoules are automatically collected in trays without manual handling.

Output Needs: Choose single-head for small-scale (e.g., lab use, 1,500/hour) or multi-head (e.g., eight-head for 12,000/hour) for large-scale production.
Ampoule Type: Ensure compatibility with open (type B/C) or closed (type D) ampoules.
Filling Mechanism: Piston pumps for high accuracy, peristaltic for sensitive liquids, or servo-driven for flexibility.
Sterility Requirements: Opt for models with laminar airflow or CIP/SIP systems for sterile applications.
Maintenance: Look for tool-free changeovers and easy-access designs for cleaning.

The Ampoule Filler Sealer for Glass Ampoules delivers superior contamination control, consistent hermetic seals, and reliable performance for sterile injectable production. Its compact design, fast changeover, and regulatory compliance (cGMP, FDA, ISO) make it the perfect choice for both small-batch and medium-scale manufacturing.

If you need specific recommendations, pricing details, or a comparison of models for a particular application (e.g., pharmaceutical vs. cosmetic), please provide more details about your requirements.

Salient Features of Ampoule Filler Sealer

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 Ampoule Filler Sealer for Glass Ampoules

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 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 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. For detailed working process please explore automatic ampoule filler video in top right section of this page.

Technical Specification of Ampoule Filler Sealer for Glass Ampoules

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 Ampoule Filler Sealer for Glass Ampoules

High accuracy in dosing, ensuring exact drug quantities.

Hermetic sealing prevents contamination and ensures product stability.

Fast changeover and high output meet large-scale production needs.

Easy integration with existing production lines and compliance with regulatory standards.

Key Features of Ampoule Filler Sealer for Glass Ampoules

Purpose and Application:
- Used for filling and sealing glass ampoules with liquid or powder drugs, ensuring protection from air, contaminants, and microorganisms.
- Suitable for industries like pharmaceuticals (e.g., injectable drugs), cosmetics (e.g., serums), biotech, veterinary, and chemical sectors.
- Handles ampoule sizes typically ranging from 0.5 ml to 30 ml, with filling capacities as low as 0.2 ml.

Operating Principle:
- Built on the slant travel mechanism, where ampoules move at an incline to accommodate variations in neck dimensions, thickness, and ovality for precise filling and sealing.
- Automated processes include ampoule loading, nitrogen purging (pre- and post-filling), liquid or powder filling, pre-heating, and sealing, with collection of sealed ampoules on a tray without manual handling.

Construction and Materials:
- Frame made of stainless steel square pipes (typically SS 304 for non-contact parts and SS 316L for contact parts) to ensure durability and compliance with cGMP standards.
- Large bottom openings for easy cleaning and maintenance.
- Equipped with safety features like gas/oxygen safety valves, pressure reducers, and stainless steel hoods to channel fumes during sealing.

Filling Mechanism:
- Uses volumetric piston pumps, servo-driven systems, or peristaltic pumps for precise dosing (0.5 ml to 25 ml in a single dose).
- Features like “no ampoule, no fill” systems minimize wastage and ensure accuracy.
- Nitrogen flushing before and after filling removes atmospheric air to maintain sterility and prevent contamination.

Sealing Process:
- Sealing is achieved using flame-based sealing (oxygen and LPG/propane) or, in advanced models, CO2 laser sealing for cleaner, non-contact sealing with minimal pollution.
- Methods include tip sealing (melting the neck to form a bead for liquid-filled ampoules) or pull sealing (for powder-filled ampoules requiring larger openings).
- Pre-heating and post-heating stations ensure smooth, uniform seals, with rollers rotating ampoules for consistent sealing.

Production Capacity:
- Available in single-head, two-head, four-head, six-head, or eight-head models, with output ranging from 10 to 250 ampoules per minute (e.g., 1,500/hour for single-head to 12,000/hour for eight-head machines).
- Example: A two-head machine fills 32–150 ampoules per minute, while an eight-head model can handle 120–200 ampoules per minute.

Automation and Control:
- Fully automatic models feature PLC systems with user-friendly HMI (e.g., Siemens touch screens) for easy operation and error detection.
- Tool-free changeover for different ampoule sizes (1 ml to 30 ml) reduces downtime.
- Optional features include CIP/SIP systems for cleaning without disassembly and laminar airflow for sterile conditions.

Additional Features:
- Neck centering during filling and sealing ensures precision.
- Waste tip collection via clippers to avoid contamination and maintain cleanliness.
- Cooling systems prevent overheating, extending machine lifespan.
- Optional laminar airflow or isolators for sterile class 100 filling.

Safety and Compliance:
- Adheres to cGMP and other regulatory standards, ensuring safety and hygiene.
- Safety features like gas circuit valves and exhaust fume aspiration systems protect operators and the environment.
- Glass particle contamination is a concern, with studies showing 89–114 particles per ampoule even with filtering, necessitating careful quality control.

FAQ for Ampoule Filler Sealer for Glass Ampoules

What is an Ampoule Filler Sealer for Glass Ampoules?

An Ampoule Filler Sealer for Glass Ampoules is a compact, automatic monobloc machine designed for precise filling and hermetic flame sealing of open-mouth glass ampoules. It is widely used in the pharmaceutical industry to fill sterile injectable liquids into ampoules ranging from 1 ml to 30 ml. The machine performs nitrogen flushing, volumetric filling, pre-heating, and gas sealing in one unit, ensuring product sterility, accurate dosing, and long shelf life while meeting cGMP, FDA, and ISO standards.

What is the filling range, speed, and accuracy of the Ampoule Filler Sealer?

The machine is available in single, two, four, and eight-head models (AFS-1 to AFS-8):

Filling range: 1 ml to 30 ml (AFS-1 & AFS-2); 1 ml to 20 ml (higher head models) – with capability as low as 0.2 ml in some configurations
Output speed: 25 ampoules/min (single head) up to 200 ampoules/min (eight heads), reaching up to 12,000 ampoules per hour
Filling accuracy: ±1% using volumetric piston pumps

It supports quick changeover with minimal parts for different ampoule sizes, making it flexible for various production needs.

What industries use the Ampoule Filler Sealer for Glass Ampoules?

This machine is primarily used in the pharmaceutical industry for sterile injectables, vaccines, antibiotics, and parenteral solutions. It is also suitable for:

Biotechnology (including biological indicators)
Cosmetics (serums and essential oils)
Veterinary medicines
Chemical and diagnostic applications

It is ideal for any product requiring contamination-free filling and hermetic sealing in glass ampoules.

What are the key features of your Ampoule Filler Sealer for Glass Ampoules?

Key features include:

Compact cGMP-compliant design with SS 316L contact parts and SS 304 non-contact parts
Nitrogen gas flushing before, during, and after filling with ampoule neck centering
Pre-warming station and precise LPG + Oxygen flame sealing
“No Ampoule – No Fill” and “No Ampoule – No Seal” safety systems to prevent wastage
Flow meters for flame regulation and dead tray for safe collection of sealed ampoules
Easy changeover, low maintenance, full accessibility, and optional laminar airflow or CIP/SIP systems

These features ensure high sterility, minimal product loss, and reliable operation in cleanroom environments.

Why choose this Ampoule Filler Sealer for glass ampoule production?

It provides an excellent combination of precision, sterility, and efficiency for pharmaceutical manufacturers. Key benefits include:

Superior contamination control through nitrogen purging and immediate hermetic flame sealing
High dosing accuracy (±1%) and consistent, leak-proof seals
Scalable models to match production volume – from lab/pilot batches to medium-scale output
Fast changeover, compact footprint, and easy integration with sterilization tunnels or downstream lines
Full regulatory compliance with cost-effective operation and reduced human intervention

It helps ensure product safety, stability, and compliance while minimizing breakage and operational costs.

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