Glass Ampoule Filler

Description

Glass ampoule filler is a specialized machine designed for filling and sealing glass ampoules, which are small, sealed vials used to store sterile liquids, such as pharmaceuticals, cosmetics, or chemicals. These machines are widely used in industries like pharmaceuticals, biotech, cosmetics, and veterinary medicine to ensure precise dosing, sterility, and contamination-free packaging. Below is an overview based on current industry information:

Production Needs: Choose based on output requirements (lab-scale vs. industrial-scale).

Ampoule Size: Ensure compatibility with desired sizes (e.g., 1 ml to 30 ml).

Regulatory Compliance: Look for cGMP, FDA, CE, or ISO certification.

Customization: Some manufacturers offer tailored solutions for specific liquids or ampoule types.

Glass Breakage Risk: Improper handling or sealing can lead to contamination or injury from glass fragments.

Maintenance: Requires regular cleaning and calibration to maintain sterile conditions.

Cost: High-speed or custom models can be expensive.

If you need specific recommendations, pricing details, or a comparison of models for a particular application (e.g., pharmaceutical vs. cosmetic), please provide more details about your requirements.

Salient Features of Glass Ampoule Filler

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 Glass Ampoule Filler

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 Glass Ampoule Filler

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 Glass Ampoule Filler

Precision and Accuracy: Ensures exact dosing, critical for pharmaceuticals to avoid over- or under-dosing.

Sterility: Hermetic sealing and nitrogen flushing protect contents from contaminants, extending shelf life.

Efficiency: High-speed automation reduces labor and increases output.

Durability: Stainless steel construction ensures long-term reliability and easy maintenance.

Flexibility: Handles various ampoule sizes and liquid types (aqueous, viscous, or powders).

Key Features of Glass Ampoule Filler

Functionality: These machines automate the process of filling glass ampoules with liquids (or sometimes powders/pellets) and sealing them, typically using a flame to melt the glass for hermetic sealing. Some models also include nitrogen purging to remove atmospheric air and prevent contamination.

Capacity and Speed: Machines vary in output, ranging from 15 to 36,000 ampoules per hour, depending on the model (e.g., single-head for lab-scale or eight-head for high-speed production). Fill volumes typically range from 0.2 ml to 30 ml.

Filling Mechanisms: Common mechanisms include volumetric piston pumps, peristaltic pumps, or servo-driven systems for precise filling. Some feature “no ampoule, no fill” systems to prevent wastage.

Sealing Process: Typically involves pre-heating, gas flushing (oxygen and LPG/propane), and final sealing with a flame. Ampoule necks are centered and rotated during sealing for uniformity.

Additional Features:
- Nitrogen flushing (pre- and post-filling) to ensure sterility.
- PLC systems and HMI for real-time monitoring and error detection.
- Easy changeover for different ampoule sizes (1 ml to 30 ml) with minimal parts.
- Slant travel mechanism to accommodate variations in ampoule neck dimensions, thickness, and ovality.

FAQ for Glass Ampoule Filler

What is a Glass Ampoule Filler?

A Glass Ampoule Filler is a fully automatic machine designed for precise filling and flame sealing of sterile liquids into glass ampoules. It is widely used in the pharmaceutical, biotechnology, veterinary, cosmetic, and chemical industries to package injectable solutions, vaccines, antibiotics, and other sterile products. The machine ensures contamination-free processing by combining nitrogen gassing, volumetric filling, pre-heating, and hermetic flame sealing in a compact cGMP-compliant design.

What is the production capacity and ampoule size range of the Glass Ampoule Filler?

The Glass Ampoule Filler is available in multiple models (single to eight heads) with output ranging from 25 to 200 ampoules per minute (up to 12,000 ampoules per hour in the highest model). It supports glass ampoule sizes from 1 ml to 30 ml (with minimum change-over parts typically for 1 ml to 10 ml). The machine delivers a filling accuracy of ±1% and is suitable for both small and large-scale sterile production.

What key features ensure sterility and performance in the Glass Ampoule Filler?

Key features include:

Nitrogen gas flushing before, during, and after filling with ampoule neck centering
“No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems
Pre-warming station for perfect, uniform flame sealing
All product contact parts made of SS 316L and non-contact parts of SS 304
Flow meters for easy flame regulation (LPG + Oxygen)
Compact cGMP design with easy cleaning and low maintenance

These features provide superior sterility, minimal product wastage, and reliable hermetic sealing.

How does the Glass Ampoule Filler work?

Washed and sterilized glass ampoules are loaded into the infeed hopper. They are transferred via starwheel to a receiving rack and then to a moving rack in an inclined (slant) position. As the ampoules travel left to right, the machine automatically performs:

Pre-gassing with nitrogen
Precise volumetric liquid filling
Post-gassing
Neck pre-heating
Rotation and flame sealing

Filled and sealed ampoules are collected upright in a delivery tray. The slant design reduces glass breakage and maintains a sterile environment throughout the process.

What are the main benefits and applications of the Glass Ampoule Filler?

This machine is ideal for the pharmaceutical, biotech, veterinary, cosmetic, and chemical industries that require sterile, contamination-free ampoule packaging.

Main benefits include:

High production output (up to 12,000 ampoules/hour) with consistent accuracy
Excellent sterility through nitrogen flushing and immediate hermetic sealing
Minimal product wastage and reduced human intervention
Quick changeover with minimum parts and easy maintenance
Compact footprint suitable for cleanrooms with full cGMP compliance
Longer product shelf life due to oxidation protection

It is a reliable and efficient solution for both pilot-scale and high-volume sterile liquid filling in glass ampoules.

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