High Speed Automatic Ampoule Filling and Sealing Machine

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.

Automatic Ampoule Filling and Sealing Machine Video

Key Features and Specifications:

• 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.

Working Process:

1. Loading: Sterilized ampoules are loaded into a slant hopper and fed via a starwheel to a transport rack.

2. Pre-Gassing: Nitrogen is flushed to displace oxygen.

3. Filling: Precise liquid dosing using piston or peristaltic pumps, with neck centering for accuracy.

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

5. Pre-Heating: Low-flame heating prepares the ampoule neck for sealing.

6. Sealing: High-flame or laser sealing forms an airtight closure, with waste glass removed by clippers.

7. Collection: Filled and sealed ampoules are automatically collected in upright trays for inspection or labeling.

Applications:

• Pharmaceuticals: Injectable drugs, vaccines, antibiotics.

• Cosmetics: Serums, essential oils.

• Biotech/Chemical: Specialized formulations requiring sterile packaging.

• Veterinary: Animal health products.

Advantages:

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

• Sterility: Aseptic conditions minimize contamination risks.

• Efficiency: High-speed operation (up to 30,000 ampoules/hour for advanced models like Syntegon’s ALF 4000) and minimal changeover time.

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

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

Considerations:

• 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.

For specific pricing or detailed technical specifications, contact manufacturers like Adinath International.

If you need a chart comparing output capacities of different head configurations or more details on a specific model, let me know!

Types of Ampoule Filling and Sealing Machine

• Laboratory Ampoule Filling Sealing Machine
• Closed 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
• Onion Skin Ampoule Filling Machine

Salient Features of Ampoule Filling and Sealing Machine

• 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 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 Automatic Ampoule Filling Machine

* 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.