High Speed Ampoule Filler

A High Speed Ampoule Filler is an advanced pharmaceutical machine designed for the rapid, precise filling and sealing of glass ampoules, primarily used in the pharmaceutical, biotech, cosmetic, and chemical industries. These machines are engineered to handle medium to large-scale production, offering high output rates while maintaining accuracy, sterility, and compliance with cGMP standards. Below is a detailed description based on the latest available information:

High Speed Ampoule Filler Video

Key Features and Specifications

• High Output Capacity: Capable of filling and sealing up to 200–400 ampoules per minute, depending on the model and configuration (e.g., 200 ampoules/min for an eight-head filler, up to 400 ampoules/min for a twelve-head model).

• Ampoule Size Compatibility: Handles a wide range of ampoule sizes, typically from 1ml to 30ml, with filling capacities from 0.5ml to 25ml in a single dose. Suitable for both open-mouth and closed-mouth ampoules.

• Filling Mechanism: Operates on volumetric piston-pump principles, with options for servo-driven or peristaltic pump systems for enhanced precision. Some models allow fill volume adjustments via touch-screen interfaces.

• Material and Build: Constructed with high-quality stainless steel 316L for contact parts and 304 for non-contact parts, ensuring durability, corrosion resistance, and compliance with cGMP standards.

• Nitrogen Flushing: Features pre- and post-nitrogen flushing units to purge atmospheric air, minimizing contamination and preserving the sterility of sensitive products like injectables.

• Sealing Process: Utilizes oxygen and LPG (propane) for sealing, with pre-warming and sealing stations equipped with specially designed rollers for uniform heating and sealing of ampoules. Safety valves and pressure reducers regulate gas flow.

• Automation and Control: Incorporates PLC systems and touch-screen HMIs for real-time monitoring, error detection, and parameter adjustments. Servo technology minimizes mechanical wear, enhancing reliability.

• Monobloc Design: Combines filling and sealing operations on a single platform, reducing footprint and improving efficiency. Some models feature a dead-tray for seamless diversion of filled and sealed ampoules.

• Minimal Changeover: Designed for quick format changes, accommodating various ampoule sizes with minimal downtime. Tool-less changeovers are available in advanced models.

• Additional Features:

  • Pre-heating units for thick glass ampoules to ensure proper sealing.

  • Flow meters for precise flame regulation.

  • Waste tip collectors made of stainless steel for efficient disposal of glass remnants.

  • Optional integration with laminar air flow or isolator systems for sterile class 100 filling.

Operational Process

1. Loading: Empty, pre-sterilized ampoules are fed into the machine’s hopper and transferred to a traveling rack or conveyor in batches (e.g., 1, 2, 4, or 8 ampoules per cycle, depending on the number of filling heads).

2. Nitrogen Purging: Ampoules are flushed with nitrogen gas to remove air and prevent contamination.

3. Filling: Precision filling needles dispense a preset volume of liquid (e.g., pharmaceuticals, cosmetics, or chemicals) using piston or peristaltic pumps. Neck centering ensures accurate filling.

4. Post-Nitrogen Flushing: Additional nitrogen flushing post-filling to maintain sterility.

5. Sealing: Ampoules are pre-warmed at a low-pressure flame station, then sealed using combustible gases (oxygen and LPG) with rollers ensuring uniform sealing.

6. Collection: Filled and sealed ampoules are automatically collected in an upright position on a tray for further processing, with waste glass diverted to a collector.

Applications

• Pharmaceuticals: Filling sterile injectables, vaccines, and other liquid or lyophilized drugs.

• Biotech and Cosmetics: Packaging serums, agro-insecticides, or veterinary medicines.

• Chemical Industry: Handling specialized chemical solutions in ampoules.

Advantages

• High Efficiency: Rapid filling and sealing reduce production time, ideal for large-scale operations.

• Precision and Sterility: Accurate dosing (±0.5% fill accuracy) and nitrogen flushing ensure product quality and safety.

• Ease of Maintenance: Large openings and stainless steel construction simplify cleaning and upkeep.

• Flexibility: Accommodates diverse ampoule sizes and product types (liquids, powders, or pellets).

• Integration: Easily integrates with upstream (e.g., washing, sterilization tunnels) and downstream (e.g., labeling, inspection) equipment for complete production lines.

Considerations for Selection

• Production Needs: Choose based on required output (e.g., 6,000–12,000 ampoules/hour for medium to large-scale production).

• Ampoule Specifications: Ensure compatibility with ampoule size, thickness, and neck dimensions.

• Filling Type: Select piston, servo, or peristaltic pump systems based on product viscosity and precision needs.

• Regulatory Compliance: Verify adherence to cGMP and FDA standards for pharmaceutical applications.

• Maintenance and Support: Opt for models with accessible designs and reliable after-sales service from manufacturers like Adinath.

Types of Ampoule Fillers

• Small Ampoule Filler
• Ampoule Filler and Sealer
• Onion Skin Ampoule Filler
• Servo Driven Ampoule Filler
• Peristaltic Pump type Ampoule Filler
• Closed Ampoule Filler
• Single Head Ampoule Filler
• Two Head Ampoule Filler
• Four Head Ampoule Filler
• Six Head Ampoule Filler
• Eight Head Ampoule Filler

Salient Features of High Speed Ampoule Filler

• Compact model as per cGMP standard.

• Higher production output up to 12000 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 High Speed 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 High Speed 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.