Automatic Ampoule Filler

Q: What ampoule sizes and output capacities does the Automatic Ampoule Filler support?

The Automatic Ampoule Filler handles ampoule sizes from 1 ml to 30 ml (1 ml to 20 ml for higher head models). Available models and approximate speeds are: AFS-1 (1 head): Up to 25 ampoules/minute AFS-2 (2 heads): Up to 50 ampoules/minute AFS-4 (4 heads): Up to 100 ampoules/minute AFS-8 (8 heads): Up to 200 ampoules/minute (up to 12,000 ampoules/hour) It offers ±1% filling accuracy with volumetric piston pumps and supports quick changeover with minimum change parts.

Q: What are the benefits of using an Automatic Ampoule Filler?

High accuracy & consistency — Delivers precise dosing with ±1% accuracy for injectable products. Superior sterility — Nitrogen flushing and immediate hermetic sealing ensure contamination-free ampoules. High efficiency — Compact design saves space and supports high-speed production with minimal operator intervention. Flexibility — Handles a wide range of ampoule sizes and liquid viscosities with fast changeover. Cost-effective operation — Reduces product wastage, labor cost, and maintenance while meeting stringent regulatory requirements.

Description

Automatic Ampoule Filler known as ampoule filling machine uses for filling and sealing of pharmaceutical glass ampoules. Our AFS series ampoule filler machine designed to fill and seal ampoules with accuracy required in pharmaceuticals. We have different machine models suitable as per different user requirements which can produce 25 ampoules per minute to 300 ampoules per minute. Our machine models are suitable to fill 1ml to 20ml ampoules with help of different change parts and machines. Ampoule Filler can be configured with different type of filling mechanisms like peristaltic pump type filling, servo driven filling or mechanical pump type filling as per user requirements. All our machine models complies as per GMP requirements for pharmaceuticals. Machine having monobloc type design in which all operations like pre gassing, product filling, post gassing, pre heating and sealing performed on one single platform. All liquid contact parts made from AISI SS 316L materials for easy cleaning and sterilization. Peristaltic pump type filling can be offered to avoid any possible cross contamination.

Sealing station is having two stage operations. In stage one preheating is performed to remove any possible droplet at inner surface of ampoule. In second stage sealing is performed through oxygen and LPG combination flame. Ampoules are rotated to 360 degree in order to perform flawless dome shaped sealing. Adinath is renowned Ampoule Filling Machines Manufacturer in India with complete range of open mouth ampoule filling machines and closed ampoule filling machines. We have laboratory scale Single Head Ampoule Filling Machine as well as production scale High Speed Ampoule Filling Machines. For average production we provide four head ampoule filler.

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 Automatic Ampoule Filler

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 Automatic 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 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 Automatic Ampoule Filler

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

Benefits of Automatic Ampoule Filler

High Accuracy: Ensures exact dosing, critical for pharmaceuticals and injectables.

Sterility: Nitrogen flushing and stainless steel construction prevent contamination.

Efficiency: High-speed models meet large-scale production demands with minimal downtime.

Ease of Use: Automated processes and minimal changeover reduce operator effort and maintenance.

Versatility: Handles a wide range of liquids, from free-flowing to viscous, and supports various ampoule sizes.

Key Features of Automatic Ampoule Filler

Purpose and Applications:
- Fills and seals glass ampoules (open or closed mouth) with liquids or, in some cases, solids, such as vaccines, antibiotics, cosmetics, or agrochemicals.
- Suitable for ampoule sizes ranging from 1ml to 30ml, with filling capacities from 0.5ml to 25ml in a single dose.

Operation Process:
- Loading: Sterilized ampoules are loaded into an infeed hopper and transferred via a starwheel or cassette to a moving rack.
- Pre-Gassing: Nitrogen gas is flushed into ampoules to displace oxygen, ensuring product stability.
- Filling: Liquid is dispensed with high precision using filling mechanisms like:
  - Peristaltic pumps (ideal for sterile or viscous liquids).
  - Servo-driven systems (for precise volume control).
  - Piston pumps (volumetric dosing for consistent filling).
- Post-Gassing: Additional nitrogen flushing post-filling to prevent contamination.
- Pre-Heating and Sealing: Ampoule necks are heated using oxygen and LPG (propane) flames and sealed to ensure an airtight closure.
- Collection: Filled and sealed ampoules are automatically collected in a tray without manual handling.

Design and Construction:
- Monobloc Design: Integrates all operations (pre-gassing, filling, post-gassing, pre-heating, sealing) on a single platform for efficiency.
- Materials: Contact parts are made of AISI 316L stainless steel for sterility and corrosion resistance; non-contact parts use AISI 304 stainless steel.
- Frame: Built on sturdy stainless steel square pipes with a matte finish for durability and aesthetic appeal.
- Accessibility: Large bottom openings and ergonomic designs allow easy cleaning and maintenance.
- Safety Features: Includes safety valves, pressure reducers for gas circuits, and a stainless steel hood to channel fumes during sealing.

Performance:
- Output: Varies by model, ranging from 25 to 36,000 ampoules per hour (e.g., single-head for lab-scale at 1,500/hour, high-speed models up to 12,000–36,000/hour).
- Precision: Accurate dosing minimizes product wastage and ensures consistent fill volumes.
- Flexibility: Adjustable for various ampoule sizes (1ml to 30ml) with minimal changeover parts.

Advanced Features:
- Neck Centering: Ensures precise alignment during gas flushing and filling to accommodate variations in ampoule neck dimensions or ovality.
- Automation: Fully automated systems reduce manual intervention, with options for PLC-based controls and pendant-type electrical panels for ease of operation.
- Sterility and Compliance: Equipped with pre-warming stations, flow meters for flame regulation, and optional safety cabinets or laminar airflow systems to maintain sterility.
- Customization: Available in single-head, two-head, four-head, six-head, or eight-head configurations to suit small, medium, or large-scale production.

Optional Features:
- Integration with upstream (e.g., washing/sterilization tunnels) and downstream equipment (e.g., inspection or labeling machines).
- Combination machines to process both ampoules and vials for enhanced flexibility.

High-voltage leak detection (HVLD) or other inspection systems for quality assurance

FAQ for Automatic Ampoule Filler

What is an Automatic Ampoule Filler?

An Automatic Ampoule Filler is a high-precision monoblock machine designed for filling and flame sealing of pharmaceutical glass ampoules in one compact platform. It performs all critical operations — nitrogen pre-gassing, liquid filling, post-gassing, pre-heating, and hermetic sealing — automatically. The machine is widely used in the pharmaceutical, biotech, cosmetic, and chemical industries for sterile injectable liquids. It is available in 1 to 8 head configurations (AFS-1 to AFS-8) and ensures high accuracy, sterility, and cGMP compliance.

What ampoule sizes and output capacities does the Automatic Ampoule Filler support?

The Automatic Ampoule Filler handles ampoule sizes from 1 ml to 30 ml (1 ml to 20 ml for higher head models). Available models and approximate speeds are:

AFS-1 (1 head): Up to 25 ampoules/minute
AFS-2 (2 heads): Up to 50 ampoules/minute
AFS-4 (4 heads): Up to 100 ampoules/minute
AFS-8 (8 heads): Up to 200 ampoules/minute (up to 12,000 ampoules/hour)

It offers ±1% filling accuracy with volumetric piston pumps and supports quick changeover with minimum change parts.

How does the Automatic Ampoule Filler ensure product sterility and quality?

The machine provides excellent sterility through:

Nitrogen gas flushing before, during, and after filling to remove oxygen and prevent oxidation/contamination.
Ampoule neck centering during gassing and filling for uniform results.
Pre-heating station followed by precise LPG + Oxygen flame sealing with 360° rotation for perfect dome-shaped hermetic seals.
“No Ampoule – No Filling” system to avoid wastage.
Contact parts made of Stainless Steel 316L and full cGMP-compliant design suitable for Class 100 cleanroom environments.

What are the main features of the Automatic Ampoule Filler?

Key features include:

Compact monoblock design with all operations on a single platform.
Option for piston pump, peristaltic pump, or servo-driven filling to avoid cross-contamination.
Pre-warming station and accurate flame regulation with flow meters.
Easy cleaning and maintenance with full open accessibility.
Low maintenance, quick format changeover, and dead tray for safe collection of sealed ampoules.
Compliance with cGMP, FDA, and international standards.

What are the benefits of using an Automatic Ampoule Filler?

High accuracy & consistency — Delivers precise dosing with ±1% accuracy for injectable products.
Superior sterility — Nitrogen flushing and immediate hermetic sealing ensure contamination-free ampoules.
High efficiency — Compact design saves space and supports high-speed production with minimal operator intervention.
Flexibility — Handles a wide range of ampoule sizes and liquid viscosities with fast changeover.
Cost-effective operation — Reduces product wastage, labor cost, and maintenance while meeting stringent regulatory requirements.

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