Four Needle Ampoule Filling Machine

A Four Needle Ampoule Filling Machine is a specialized pharmaceutical device designed for high-precision filling and sealing of glass ampoules, typically used for injectable liquids, vaccines, serums, or other sensitive products. Below is a detailed description based on the operational principles and features of such machines, tailored to the query:

Being a top producer of four head ampoule filling machines, we offer reliable, user-friendly devices that require minimum maintenance. One of the top exporters of ampoule filling machines from India is Adinath International.

Four Needle Ampoule Filling Machine Video

Description of Ampoule Filling Machine

• Purpose and Application:

  This machine is engineered for filling and sealing open-mouth or closed-mouth glass ampoules with liquid or powder formulations. It is widely used in industries such as pharmaceuticals, cosmetics, biotechnology, and chemical manufacturing for packaging injectable drugs, serums, or light-sensitive chemicals. The four-needle design enhances efficiency by allowing simultaneous filling of multiple ampoules, making it suitable for medium to large-scale production.

• Construction and Design:

  • Material: Built with a robust frame, typically made of stainless steel 316L for contact parts to ensure compliance with cGMP standards, ensuring durability and resistance to corrosion. Non-contact parts are often made of stainless steel 304.

  • Compact Design: Features a monobloc design integrating filling and sealing units, minimizing space requirements and ensuring seamless operation.

  • Nitrogen Flushing: Equipped with pre- and post-nitrogen flushing units to purge air and prevent contamination or oxidation of sensitive products.

  • Slant Rack Movement: Ampoules are transported on an inclined rack system, allowing precise handling during filling and sealing processes.

• Filling Mechanism:

  • Four Nozzles: The machine uses four filling needles to dispense liquid or powder into ampoules simultaneously, increasing throughput. It supports filling volumes from 0.5 ml to 25 ml in a single dose, with flexibility for ampoule sizes ranging from 1 ml to 30 ml.

  • Filling Options: Offers multiple filling mechanisms, including:

    • Peristaltic Pump: Ideal for sterile and low-viscosity liquids, minimizing contamination risks.

    • Piston Pump: Suitable for precise volumetric filling of thicker liquids.

    • Servo-Controlled: Provides high accuracy for customized filling requirements.

  • Neck Centering: Ensures accurate alignment of ampoule necks during filling to prevent spillage or waste.

  • No Ampoule, No Fill: A safety feature that stops liquid discharge if no ampoule is present, reducing waste.

• Sealing Process:

  • Two-Stage Sealing:

    1. Pre-Heating: A low-pressure flame warms the ampoule to remove residual droplets and prepare it for sealing.

    2. Sealing: Uses a combination of LPG (propane) and oxygen gas with clippers or rollers to rotate ampoules, ensuring a 360-degree flame for a secure, uniform seal.

  • Sealing Flexibility: Can handle both open-mouth (Type B) and closed-mouth (Type C) ampoules, with some models offering flame sealing, crimp sealing, or snap-off sealing options.

• Production Capacity:

  • Capable of filling 50 to 100 ampoules per minute (approximately 6,000 ampoules per hour), depending on the model and liquid viscosity. High-speed versions can achieve up to 12,000 ampoules per hour.

  • The machine processes four ampoules per cycle, advancing them through synchronized starwheel or cassette systems.

• Key Features:

  • cGMP Compliance: Meets stringent pharmaceutical standards for hygiene and quality.

  • Minimal Changeover Time: Tool-less format changes for different ampoule sizes, enhancing operational efficiency.

  • Pre-Warming Station: Ensures consistent sealing for thick glass ampoules.

  • Flow Meters: Regulate flames for precise sealing.

  • Laminar Air Flow (Optional): Provides a sterile Class 100 environment for filling.

  • Waste Tip Collection: Clipped ampoule tips are ejected into a separate stainless steel container.

  • Cooling System: Prevents overheating, extending machine lifespan.

  • PLC Integration: Modern models feature programmable logic controllers (PLCs) for real-time monitoring and parameter adjustments.

• Operational Workflow:

  1. Loading: Sterilized, empty ampoules are loaded into an infeed hopper and transferred via a starwheel or cassette to a moving rack.

  2. Pre-Gassing: Nitrogen is flushed to remove oxygen from the ampoule.

  3. Filling: Four needles dispense the precise volume of liquid or powder.

  4. Post-Gassing: Additional nitrogen flushing to ensure sterility.

  5. Pre-Heating: A low-pressure flame prepares the ampoule for sealing.

  6. Sealing: Rollers rotate the ampoule while a high-pressure flame seals it.

  7. Collection: Filled and sealed ampoules are collected upright on a tray for further processing.

• Applications:

  • Pharmaceuticals: Filling injectable drugs, vaccines, and parenterals.

  • Cosmetics: Packaging serums, oils, or high-end liquid products.

  • Chemicals: Storing light- or air-sensitive substances.

  • Food and Beverage: Filling single-dose liquid preservatives or flavorings.

• Advantages:

  • High precision and accuracy in filling and sealing.

  • Reduced contamination risk due to nitrogen flushing and sterile design.

  • Fast production rates with minimal maintenance.

  • Versatile for various ampoule sizes and liquid types.

  • Easy cleaning and accessibility for maintenance.

• Customization and Flexibility:

  • Adjustable power voltage to meet regional requirements.

  • Optional features like inbuilt laminar airflow, safety cabinets, or isolators for enhanced sterility.

  • Can be integrated with upstream (washing, sterilization tunnels) and downstream (labeling, inspection) equipment for a complete production line.

This description provides a comprehensive overview of a four-needle ampoule filling machine, focusing on its design, functionality, and applications while incorporating relevant details from the provided search results. If you need specific details, such as pricing, a particular model, or a chart comparing features, please let me know!

Salient Features of Ampoule Filling Machine

• Compact cGMP model.

• Higher output up to 6000 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 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.

Technical Specification of Four Needle Ampoule Filler

* 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.