High Speed Automatic Ampoule Filling and Sealing Machine

Q: What is the production capacity and ampoule size range of the High-Speed Ampoule Filling Machine?

The machine supports multiple models with varying speeds: AFS-8 (Eight Heads) : Up to 200 ampoules per minute (approx. 12,000 ampoules per hour) AFS-4 (Four Heads) : Up to 100 ampoules/min AFS-2 (Two Heads) : Up to 50 ampoules/min AFS-1 (Single Head) : Up to 25 ampoules/min It handles ampoule sizes from 1 ml to 20/30 ml (model dependent) with a filling volume range of 0.5 ml to 25 ml and delivers ±1% filling accuracy using volumetric piston pumps. Minimum change-over parts are required for different sizes.

Q: What key features ensure high speed, accuracy, and sterility?

Key features include: Nitrogen pre-gassing and post-gassing with ampoule neck centering to prevent oxidation “No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems Pre-warming/pre-heating station for perfect flame sealing using LPG + Oxygen All product contact parts in SS 316L and non-contact parts in SS 304 Flow meters for precise flame regulation and variable speed control PLC/HMI options for easy operation and servo-driven systems for higher precision Compact cGMP design with easy cleaning and low maintenance These features minimize wastage, ensure superior sterility, and support high-speed continuous operation.

Description

High-speed Automatic Ampoule Filling and Sealing Machine are advanced systems designed for efficient, precise, and sterile filling and sealing of glass or plastic ampoules in pharmaceutical, biotech, cosmetic, and chemical industries. These machines are critical for high-volume production of injectable drugs, vaccines, serums, and other sensitive liquids, ensuring accuracy, minimal contamination, and compliance with cGMP standards.

Maintenance: Requires regular cleaning and calibration for sterile operations.

Customization: Servo-driven and peristaltic pump models offer flexibility but may increase costs.

Energy Efficiency: Modern designs optimize power and gas usage.

Salient Features of Ampoule Filling Sealing 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 Ampoule Filling and 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. For detailed working process please explore Automatic Ampoule Filler Video in top right section of this page.

Technical Specification of Ampoule Filling and Sealing Machine

Model Name	AFS-8
Production Speed	Up to 200 ampules/minute
Ampoule Sizes	1 ml to 20 ml
Filling Error	± 1%
Sealing Gas	LPG and Oxygen (O₂)
Nitrogen Gas	Pre & Post Nitrogen
Power Load	2 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	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 Automatic Ampoule Filling and Sealing Machine

High Precision: Fill accuracy of ±0.5% ensures consistent dosing.

Sterility: Aseptic conditions minimize contamination risks.

Efficiency: High-speed operation

Versatility: Handles various ampoule sizes and materials (glass/plastic).

Automation: Reduces manual labor, errors, and operational costs.

Key Features of Automatic Ampoule Filling and Sealing Machine

Output Capacity: Ranges from 80 to 300 ampoules per minute, depending on the model and number of filling heads (e.g., single, two, four, six, or eight heads). For instance, an eight-head machine can achieve up to 12,000 ampoules per hour for 1-10ml sizes.

Filling Volume: Adjustable from 0.5ml to 30ml, accommodating ampoule sizes of 1ml to 30ml.

Filling Mechanisms: Options include:
- Piston Pumps (volumetric, for precise dosing).
- Peristaltic Pumps (ideal for sterile applications, adjustable via touch-screen in servo-driven models).
- Servo-Driven Systems (offer zero mechanical adjustments and high precision).

Sealing Process: Typically involves a two-stage process:

1. Pre-heating: Low-flame heating to remove liquid droplets from the ampoule’s inner surface.
2. Sealing: Uses oxygen-LPG or thermal/laser methods to melt glass for an airtight seal, often with 360° ampoule rotation for uniform dome-shaped sealing.

Automation: Fully automatic models minimize human intervention, reducing contamination risks. Features include:

- In-feed Hopper and Starwheel: For automatic ampoule loading and transport.
- Pre- and Post-Gassing: Nitrogen flushing to remove oxygen and extend shelf life.
- No-Ampoule-No-Fill Safety: Prevents liquid spillage.
- PLC/HMI Control: For precise fill volume adjustments and operational ease.

Construction: Built with stainless steel 316L for contact parts and 304 for non-contact parts, ensuring durability and compliance with cGMP standards.

Versatility: Handles open-mouth and closed-mouth ampoules, with tool-less format changes for different sizes. Suitable for liquids, powders, and pellets.

Hygienic Design: Enclosed systems with laminar flow compatibility and easy-to-clean surfaces for sterile environments.

FAQ for Automatic Ampoule Filling and Sealing Machine

What is a High-Speed Automatic Ampoule Filling and Sealing Machine?

The High-Speed Automatic Ampoule Filling and Sealing Machine is a fully automatic, multi-head pharmaceutical equipment designed for high-volume sterile filling and flame sealing of injectable liquids into glass ampoules. It integrates pre-gassing, precise filling, post-gassing, neck pre-heating, and sealing in a compact cGMP-compliant design. Primarily available in the AFS-8 (Eight Head) configuration, it is ideal for large-scale production in pharmaceutical, biotechnology, veterinary, and cosmetic industries while maintaining sterility and high output.

What is the production capacity and ampoule size range of the High-Speed Ampoule Filling Machine?

The machine supports multiple models with varying speeds:

AFS-8 (Eight Heads): Up to 200 ampoules per minute (approx. 12,000 ampoules per hour)
AFS-4 (Four Heads): Up to 100 ampoules/min
AFS-2 (Two Heads): Up to 50 ampoules/min
AFS-1 (Single Head): Up to 25 ampoules/min

It handles ampoule sizes from 1 ml to 20/30 ml (model dependent) with a filling volume range of 0.5 ml to 25 ml and delivers ±1% filling accuracy using volumetric piston pumps. Minimum change-over parts are required for different sizes.

What key features ensure high speed, accuracy, and sterility?

Key features include:

Nitrogen pre-gassing and post-gassing with ampoule neck centering to prevent oxidation
“No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems
Pre-warming/pre-heating station for perfect flame sealing using LPG + Oxygen
All product contact parts in SS 316L and non-contact parts in SS 304
Flow meters for precise flame regulation and variable speed control
PLC/HMI options for easy operation and servo-driven systems for higher precision
Compact cGMP design with easy cleaning and low maintenance

These features minimize wastage, ensure superior sterility, and support high-speed continuous operation.

How does the High-Speed Automatic Ampoule Filling and Sealing Machine work?

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

Pre-gassing with nitrogen
Precise volumetric liquid filling
Post-gassing
Neck pre-heating
High-speed rotation and flame sealing (with sealing clipper for clean dome-shaped seals)

Filled and sealed ampoules are collected upright in a delivery tray. The slant design reduces glass breakage and contamination risks while enabling high throughput.

What are the main benefits and applications of this High-Speed Ampoule Filler?

This machine is perfect for large-scale sterile injectable production in the pharmaceutical, biotechnology, veterinary, cosmetic, and chemical industries.

Main benefits include:

Very high output (up to 12,000 ampoules/hour) with consistent ±1% accuracy
Excellent sterility through nitrogen flushing and immediate sealing
Reduced product wastage and minimal human intervention
Quick changeover, easy maintenance, and compact footprint
Full cGMP compliance with low power consumption (2 H.P. for AFS-8)
Cost-effective for commercial manufacturing while ensuring regulatory standards

It is the ideal choice for companies looking to scale up production without compromising quality.

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