Automatic Ampoule Filler

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.

Automatic Ampoule Filler Videos

Key Features and Functionality:

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

6. 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.

Benefits:

• 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.

Typical Applications:

• Filling and sealing of injectable drugs, vaccines, and biologics in pharmaceuticals.

• Packaging of cosmetics, veterinary medicines, and chemical solutions.

• Laboratory-scale production to high-volume industrial manufacturing.

Types of Ampoule Fillers

• Small Ampoule Filler
• Ampoule Filler and Sealer
• Onion Skin Ampoule Filler
• Servo Driven Ampoule Filler
• Peristaltic Pump type Ampoule Filler
• Closed Ampoule Filler
• Single Head Ampoule Filler
• Two Head Ampoule Filler
• Four Head Ampoule Filler
• Six Head Ampoule Filler
• Eight Head Ampoule Filler

Salient Features of Automatic Ampoule Filler

• Compact model as per cGMP standard.

• Higher production 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.

Process Operation of Automatic Ampoule Filler 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 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 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.