Four Needle Ampoule Filling Machine

Q: How does the Four Needle Ampoule Filling Machine work?

The machine operates on the slant traveling principle for gentle ampoule handling and reduced glass breakage. The automated process includes: Automatic loading of sterilized ampoules from the hopper Nitrogen pre-flushing to remove oxygen Simultaneous filling through four needles with neck centering Nitrogen post-flushing Neck pre-warming Accurate flame sealing using LPG + Oxygen burners It features “No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems to prevent wastage and ensure maximum sterility.

Description

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.

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.

- 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 Four Needle Ampoule Filling Machine

Compact cGMP model.
Higher output up to 6000 Ampoules per hour.
Full accessibility allows easy maintenance.
Flow Meters for regulating flames easily.
“No Ampoule – No Filling” system.
Machine equipped with pre-warming station.

Ampoule neck centering during gas flushing and filling operations.
Possibility of nitrogen gas flushing before, during and after filling.
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.
Minimum change over time, little maintenance, easy cleaning.

Working Principle of Four Needle 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.

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

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

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

Post-Gassing: Additional nitrogen flushing to ensure sterility.

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

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

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

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.

Technical Specification of Four Needle Ampoule Filling Machine

Model Name	AFS-4
Production Speed	Up to 100 ampules/minute
Ampoule Sizes	1 ml to 10 ml
Filling Error	± 1%
Sealing Gas	LPG and Oxygen (O₂)
Nitrogen Gas	Pre & Post Nitrogen
Power Load	1 H. P.
Power Voltage	230 Volts, Single Phase, 50 Hertz
Contact Parts	Made from Stainless Steel 316L
Non-Contact Parts	Made from Stainless Steel 304
Machine Size	1200mm (L) x 1070mm (W) x 965mm (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 Four Needle Ampoule Filling Machine

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.

Key Features of Four Needle Ampoule Filling Machine

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.

FAQ for Four Needle Ampoule Filling Machine

What is a Four Needle Ampoule Filling Machine?

A Four Needle Ampoule Filling Machine (also known as Four Head Ampoule Filler Sealer) is a fully automatic monobloc machine designed for high-precision filling and flame sealing of sterile liquid injectables into glass ampoules. It uses four filling needles working simultaneously and integrates nitrogen flushing (pre- and post-filling), volumetric piston filling, neck pre-heating, and LPG + Oxygen flame sealing in one compact unit. This model is ideal for medium to large-scale pharmaceutical production and meets cGMP, USFDA, WHO, and international regulatory standards.

What is the production capacity of the Four Needle Ampoule Filling Machine?

The Four Needle Ampoule Filling Machine (Model AFS-4) has a production capacity of up to 100 ampoules per minute (approximately 6,000 ampoules per hour). It supports ampoule sizes from 1ml to 20ml (model dependent) with a filling range of 0.5ml to 25ml and maintains excellent filling accuracy of ±1%. This makes it suitable for medium to high-volume injectable manufacturing.

How does the Four Needle Ampoule Filling Machine work?

The machine operates on the slant traveling principle for gentle ampoule handling and reduced glass breakage. The automated process includes:

Automatic loading of sterilized ampoules from the hopper
Nitrogen pre-flushing to remove oxygen
Simultaneous filling through four needles with neck centering
Nitrogen post-flushing
Neck pre-warming
Accurate flame sealing using LPG + Oxygen burners

It features “No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems to prevent wastage and ensure maximum sterility.

What are the key features of the Four Needle Ampoule Filling Machine?

Key features include:

Four needle / four head monobloc design for higher productivity
Nitrogen flushing before, during, and after filling
Precision piston pumps for accurate dosing
Tool-less quick changeover with minimal parts
All product contact parts made of SS 316L
Slant design for smooth movement and low glass particle generation
Pre-heating station and precise flame control with flow meters
Compact footprint with easy cleaning and maintenance
Optional PLC/HMI with SCADA compatibility

What are the main benefits of the Four Needle Ampoule Filling Machine?

Main benefits include:

Four times higher output compared to single needle machines (up to 100 ampoules/min)
Excellent filling accuracy (±1%) with minimal product wastage
Gentle handling reduces glass breakage and contamination risk
Ideal balance between speed and cost for medium to large batches
Fast format changeover and easy validation
Compact design suitable for cleanroom environments
Full cGMP compliance and reliable high-performance operation

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