Automatic Ampoule Filling Sealing Machine

Q: What is an Automatic Ampoule Filling Sealing Machine?

An Automatic Ampoule Filling Sealing Machine is a compact, high-precision monoblock system that automatically fills and flame-seals glass ampoules in a single operation. It is designed for sterile injectable liquids in the pharmaceutical, biotech, veterinary, cosmetic, and chemical industries. The machine works on the slant travel principle , handling ampoules gently while performing nitrogen gassing (pre, during & post-filling), volumetric filling, pre-heating, and hermetic flame sealing using LPG & Oxygen. It ensures contamination-free processing and complies with cGMP standards.

Q: What ampoule sizes and production speeds does the Automatic Ampoule Filling Sealing Machine support?

The machine supports ampoule sizes from 1 ml to 30 ml (1 ml to 20 ml for higher head models) with a filling range of 0.5 ml to 25 ml. It is available in 1 to 8 head models: 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 (approx. 12,000 ampoules/hour) It delivers ±1% filling accuracy with volumetric piston pumps and supports quick format changeover with minimum change parts.

Q: What are the main benefits of using an Automatic Ampoule Filling Sealing Machine?

High efficiency — Achieves up to 12,000 ampoules per hour with minimal operator intervention. Superior accuracy & sterility — ±1% filling accuracy and hermetic sealing protect product integrity. Gentle handling — Slant travel principle accommodates variations in ampoule neck dimensions and reduces breakage. Cost-effective — Reduces product wastage, labor costs, and changeover time while meeting FDA/cGMP requirements. Flexibility — Suitable for a wide range of liquid injectables and easy integration into complete production lines.

Description

Automatic Ampoule Filling Sealing Machine is a specialized, high-precision piece of equipment used primarily in the pharmaceutical, biotech, cosmetic, veterinary, and chemical industries for filling and sealing glass ampoules. These machines are designed to handle the sterile and accurate filling of liquids or powders into ampoules, ensuring contamination-free processing and compliance with cGMP standards. The machine operates on the slant travel principle, where ampoules move at an angle during filling and sealing to accommodate variations in neck dimensions, thickness, and ovality. Below is a detailed description based on their design, operation, and features:

Infeed Hopper and Star Wheel: Facilitates smooth ampoule feeding and transfer to the transport rack.

Filling Station: Equipped with multiple nozzles (up to 16 heads) for high-speed filling, using volumetric piston pumps or servo-based systems for precision.

Sealing Station: Includes pre-heating and sealing burners, with safety valves and pressure reducers for gas control.

Conveyor System: Linear or wire mesh conveyors integrate with upstream (sterilization tunnels) and downstream (inspection or labeling) equipment.

Control System: PLC and HMI panels for automated volume adjustments, operational monitoring, and error detection.

Optional Features: Laminar Air Flow (LAF) or isolator systems for sterile class 100 filling, dual flow meters for gas regulation, and in-process control (IPC) for real-time weight and seal checks.

Salient Features of Automatic Ampoule Filling Sealing Machine

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 Filling Sealing 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 Automatic Ampoule Filling Sealing 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 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 Automatic Ampoule Filling Sealing Machine

High Precision: Ensures accurate fill volumes (±0.5%) with no overfilling or underfilling, minimizing waste.

Sterility: Nitrogen flushing and sealed environments protect contents from contamination and environmental factors like dust and microorganisms.

Efficiency: High-speed models (e.g., 7200–9000 ampoules/hour for 4–6 head machines) support large-scale production with minimal changeover time.

Durability: Stainless steel construction and efficient cooling systems extend machine lifespan, making it a cost-effective long-term investment.

Flexibility: Handles various ampoule sizes and types (open or closed), with easy integration into existing production lines.

Key Features of Automatic Ampoule Filling Sealing Machine

Construction: Built with a stainless steel (SS 316L for contact parts, SS 304 for non-contact parts) frame and coverings, ensuring durability, corrosion resistance, and compliance with hygienic standards. The design often includes a matt finish for aesthetic appeal and ease of cleaning.

Capacity: Suitable for filling ampoules ranging from 1ml to 30ml, with some models handling up to 25ml in a single dose. Output varies from 15 to 200 ampoules per minute, depending on the number of filling heads (1, 2, 4, 6, 8, or 16).

Automation: Fully automatic models minimize manual intervention, reducing human error and contamination risks. PLC (Programmable Logic Controller) and HMI (Human-Machine Interface) control panels allow for precise volume adjustments and operational monitoring.

Versatility: Capable of filling aqueous solutions, powders, or pellets, with options for nitrogen flushing before and after filling to prevent oxidation and contamination.

FAQ for Automatic Ampoule Filling Sealing Machine

What is an Automatic Ampoule Filling Sealing Machine?

An Automatic Ampoule Filling Sealing Machine is a compact, high-precision monoblock system that automatically fills and flame-seals glass ampoules in a single operation. It is designed for sterile injectable liquids in the pharmaceutical, biotech, veterinary, cosmetic, and chemical industries. The machine works on the slant travel principle, handling ampoules gently while performing nitrogen gassing (pre, during & post-filling), volumetric filling, pre-heating, and hermetic flame sealing using LPG & Oxygen. It ensures contamination-free processing and complies with cGMP standards.

What ampoule sizes and production speeds does the Automatic Ampoule Filling Sealing Machine support?

The machine supports ampoule sizes from 1 ml to 30 ml (1 ml to 20 ml for higher head models) with a filling range of 0.5 ml to 25 ml. It is available in 1 to 8 head models:

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 (approx. 12,000 ampoules/hour)

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

How does the Automatic Ampoule Filling Sealing Machine ensure sterility and product quality?

The machine maintains high sterility through:

Nitrogen gas flushing before, during, and after filling with ampoule neck centering to prevent oxidation and contamination.
Pre-warming station followed by precise LPG + Oxygen flame sealing with rotating rollers for uniform, hermetic dome-shaped seals.
“No Ampoule – No Filling” and “No Ampoule – No Seal” safety interlocks to avoid wastage and errors.
Full compatibility with Laminar Air Flow (LAF) or isolator systems for Class 100 aseptic filling. Contact parts are made of Stainless Steel 316L, ensuring easy cleaning and validation.

What are the key features of the Automatic Ampoule Filling Sealing Machine?

Key features include:

Compact cGMP-compliant monoblock design with full accessibility for maintenance.
PLC + HMI with variable speed drive and in-process control (IPC) for real-time monitoring.
Dual flow meters for accurate flame regulation and safety valves for gas control.
Pre-heating station and 360° ampoule rotation during sealing.
Minimum changeover time, low maintenance, and easy cleaning.
Optional servo-driven or peristaltic pumps for sensitive products.

What are the main benefits of using an Automatic Ampoule Filling Sealing Machine?

High efficiency — Achieves up to 12,000 ampoules per hour with minimal operator intervention.
Superior accuracy & sterility — ±1% filling accuracy and hermetic sealing protect product integrity.
Gentle handling — Slant travel principle accommodates variations in ampoule neck dimensions and reduces breakage.
Cost-effective — Reduces product wastage, labor costs, and changeover time while meeting FDA/cGMP requirements.
Flexibility — Suitable for a wide range of liquid injectables and easy integration into complete production lines.

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Automatic Ampoule Filling Sealing Machine

Description

Salient Features of Automatic Ampoule Filling Sealing Machine

Working Principle of Automatic Ampoule Filling Sealing Machine

Technical Specification of Automatic Ampoule Filling Sealing Machine

Types of Ampoule Filling Machine

Applications of Ampoule Filling Machine

Advantages of Automatic Ampoule Filling Sealing Machine

High Precision: Ensures accurate fill volumes (±0.5%) with no overfilling or underfilling, minimizing waste.

Sterility: Nitrogen flushing and sealed environments protect contents from contamination and environmental factors like dust and microorganisms.

Efficiency: High-speed models (e.g., 7200–9000 ampoules/hour for 4–6 head machines) support large-scale production with minimal changeover time.

Durability: Stainless steel construction and efficient cooling systems extend machine lifespan, making it a cost-effective long-term investment.

Flexibility: Handles various ampoule sizes and types (open or closed), with easy integration into existing production lines.

Key Features of Automatic Ampoule Filling Sealing Machine

FAQ for Automatic Ampoule Filling Sealing Machine

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