Compact Ampoule Filling Machine

Q: What is a Compact Ampoule Filling Machine?

A Compact Ampoule Filling Machine is a fully automatic, space-saving monoblock system designed for precise filling and flame sealing of glass ampoules in a single compact unit. It performs nitrogen gassing (pre, during & post-filling), volumetric liquid filling, pre-heating, and hermetic sealing on one platform. This makes it ideal for pharmaceutical, biotech, veterinary, and cosmetic industries where cleanroom space is limited, such as R&D labs, pilot plants, and small-to-medium production facilities.

Q: Why should I choose a Compact Ampoule Filling Machine?

The biggest advantage is its small footprint while offering full-scale performance. By combining filling and sealing in one monoblock unit, it significantly reduces the required cleanroom space compared to separate machines. It is perfect for facilities with limited area, pilot production, or when you want a cost-effective yet high-precision solution without sacrificing sterility or output quality.

Q: What are the main benefits of the Compact Ampoule Filling Machine?

Space-saving design — Compact monoblock construction with minimal footprint. High efficiency — Fast changeover and high output in limited space. Superior accuracy & sterility — ±1% filling accuracy and hermetic sealing protect sensitive injectables. Gentle handling — Slant traveling principle reduces glass breakage. Low operating cost — Reduced space requirement, lower maintenance, and minimal product wastage while meeting FDA and cGMP standards.

Description

Compact Ampoule Filling Machine is a specialized pharmaceutical machine designed for precise filling and sealing of glass ampoules, typically used for injectable liquids, vaccines, or other sterile solutions. The Compact Ampoule Filling Machine is a high-precision, cGMP-compliant monoblock machine designed for automatic filling and flame sealing of pharmaceutical glass ampoules. Engineered for facilities with limited cleanroom space, this machine integrates filling and sealing operations on a single compact platform, delivering excellent performance with a minimal footprint. Built on the advanced slant traveling principle, the Compact Ampoule Filling Machine ensures gentle handling of ampoules while maintaining high-speed production. It is ideal for sterile injectable liquids in the pharmaceutical, biotech, veterinary, cosmetic, and chemical industries.

Purpose: Fills and seals glass ampoules (open or closed types) with liquid or powder in pharmaceutical, biotech, cosmetic, or chemical industries.

No Ampoule, No Fill: Prevents liquid wastage.

Nitrogen Flushing: Before and after filling to minimize contamination.

Quick Changeover: Minimal parts change for different ampoule sizes (1ml to 30ml).

Accessibility: Designed for easy maintenance and cleaning, with large bottom openings or ergonomic geometry.

Optional Features: Laminar Air Flow, safety cabinets, or isolators for enhanced sterility; check-weighing systems for quality control.

Applications: Ideal for small to medium-scale production, R&D, or lab-scale operations, handling aqueous solutions, powders, or pellets.

Salient Features of Compact Ampoule Filling 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 Compact Ampoule Filling 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 Compact 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 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 Compact Ampoule Filling Machine

High precision and sterile operation ensure product safety.

Compact footprint suits space-constrained facilities.

Versatile for various ampoule sizes and types (open or pre-sterilized closed ampoules).

Easy integration with upstream (e.g., sterilization tunnels) and downstream (e.g., labeling) equipment.

Key Features of Compact Ampoule Filling Machine

Purpose: Fills and seals glass ampoules (open or closed types) with liquid or powder in pharmaceutical, biotech, cosmetic, or chemical industries.

Design:
- Compact cGMP Model: Space-efficient, adhering to Current Good Manufacturing Practices (cGMP) for sterile environments.
- Monobloc Construction: Integrates filling, sealing, and sometimes nitrogen purging in a single unit, reducing contamination risks.
- Material: Contact parts made of AISI SS 316L for GMP compliance; non-contact parts typically AISI SS 304.

Capacity:
- Fills ampoules from 0.5ml to 30ml in single dosing.
- Output ranges from 15 to 150 ampoules per minute, depending on model (e.g., single-head to eight-head configurations).

Operation:
- Filling Mechanism: Utilizes piston pumps, servo-driven systems, or peristaltic pumps for high accuracy (±0.5% fill precision).
- Process: Ampoules are loaded via an infeed hopper, transported via starwheel or rack, and undergo pre-gassing (nitrogen), filling, post-gassing, pre-heating, and sealing.
- Sealing: Uses oxygen and LPG (propane) for flame sealing, with safety valves and exhaust systems.
- Automation: Features PLC-based controls with HMI (Human-Machine Interface) for easy operation and volume adjustments.

FAQ for Compact Ampoule Filling Machine

What is a Compact Ampoule Filling Machine?

A Compact Ampoule Filling Machine is a fully automatic, space-saving monoblock system designed for precise filling and flame sealing of glass ampoules in a single compact unit. It performs nitrogen gassing (pre, during & post-filling), volumetric liquid filling, pre-heating, and hermetic sealing on one platform. This makes it ideal for pharmaceutical, biotech, veterinary, and cosmetic industries where cleanroom space is limited, such as R&D labs, pilot plants, and small-to-medium production facilities.

What ampoule sizes and production capacities does the Compact Ampoule Filling Machine support?

The Compact Ampoule Filling Machine handles ampoule sizes from 1 ml to 30 ml 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 (12,000 ampoules/hour)

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

Why should I choose a Compact Ampoule Filling Machine?

The biggest advantage is its small footprint while offering full-scale performance. By combining filling and sealing in one monoblock unit, it significantly reduces the required cleanroom space compared to separate machines. It is perfect for facilities with limited area, pilot production, or when you want a cost-effective yet high-precision solution without sacrificing sterility or output quality.

How does the Compact Ampoule Filling Machine ensure sterility and product safety?

The machine ensures high sterility through:

Nitrogen flushing before, during, and after filling with ampoule neck centering to prevent oxidation and contamination.
Pre-heating station and precise LPG + Oxygen flame sealing with rotating rollers for strong, leak-proof hermetic seals.
“No Ampoule – No Filling” and “No Ampoule – No Seal” interlocks to avoid wastage.
Stainless Steel 316L contact parts and open cGMP design suitable for Class 100 laminar airflow environments.

What are the main benefits of the Compact Ampoule Filling Machine?

Space-saving design — Compact monoblock construction with minimal footprint.
High efficiency — Fast changeover and high output in limited space.
Superior accuracy & sterility — ±1% filling accuracy and hermetic sealing protect sensitive injectables.
Gentle handling — Slant traveling principle reduces glass breakage.
Low operating cost — Reduced space requirement, lower maintenance, and minimal product wastage while meeting FDA and cGMP standards.

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