Injection Ampoule Filling Machine

Q: What models are available and what is their production capacity?

We offer four standard models: AFS-1 (Single Head) : Up to 25 ampoules per minute (~1,500 per hour) AFS-2 (Two Heads) : Up to 50 ampoules per minute AFS-4 (Four Heads) : Up to 100 ampoules per minute (~6,000 per hour) AFS-8 (Eight Heads) : Up to 200 ampoules per minute (~12,000 per hour) Custom high-speed models are available up to 36,000 ampoules per hour . Filling range is 0.5ml to 25ml with ±1% accuracy. Ampoule size compatibility: 1ml–30ml (AFS-1) and 1ml–20ml (higher models).

Q: How does the Injection Ampoule Filling Machine work?

The machine operates on the slant traveling principle , which gently handles ampoules and reduces glass breakage and particle contamination. The process includes: Automatic loading of sterilized ampoules from the hopper Nitrogen pre-flushing to remove oxygen Precise volumetric filling using piston pumps with neck centering Nitrogen post-flushing Neck pre-warming Flame sealing with LPG + Oxygen burners It features a “No Ampoule – No Filling” system and automatic collection of sealed ampoules. The slant design and automated steps ensure high sterility and minimal human intervention.

Q: What are the key features of the Injection Ampoule Filling Machine?

Key features include: Nitrogen flushing before, during, and after filling to prevent oxidation SS 316L product contact parts and SS 304 non-contact parts Tool-less quick changeover with minimal parts Ampoule neck centering during flushing and filling Pre-warming station and flame flow meters for perfect sealing “No Ampoule – No Fill/Seal” safety system Compatibility with laminar airflow and isolator systems Optional PLC/HMI and SCADA for advanced control Easy cleaning, low maintenance, and full cGMP compliance

Description

Injection Ampoule Filling Machine is a specialized piece of pharmaceutical equipment designed to fill and seal glass ampoules with injectable liquid drugs, ensuring precision, sterility, and compliance with industry standards. These machines are widely used in pharmaceutical, biotech, chemical, and cosmetic industries to handle liquids ranging from free-flowing to viscous oils, typically in ampoules of 1ml to 30ml capacity. Injection Ampoule Filling Machines are critical for high-precision, sterile, and efficient production of injectable pharmaceuticals and other sensitive liquids. Their robust design, advanced automation, and compliance with global standards make them indispensable in modern pharmaceutical manufacturing. Below is a detailed description based on the operational principles, features, and advantages of these machines:

Designed to meet cGMP, US FDA, CE, and ISO 9187-1:2010 standards for injectable equipment.

Contact parts use FDA-approved materials to ensure safety and non-reactivity with drugs.

Optional 21 CFR Part 11 compliance for electronic records and signatures.

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

Purpose: The machine automates the filling and sealing of glass ampoules, which are small, sealed vials used to store injectable pharmaceuticals, vaccines, or other sensitive liquids. The hermetic sealing protects contents from air, contaminants, and microorganisms, ensuring sterility and extended shelf life.

Operation: The machine operates on the principle of slant travel of ampoules during filling and sealing to accommodate variations in ampoule neck dimensions, thickness, and ovality. Ampoules are transported via a wire mesh conveyor belt or starwheel system, ensuring precise movement through various stations:

- Loading: Sterilized, empty ampoules are fed automatically from a hopper or tray onto a conveyor or rack.
- Pre-Nitrogen Flushing(optional): Nitrogen gas is injected to displace air, reducing oxidation and contamination risks.
- Filling: Liquid is precisely dosed using filling mechanisms such as piston pumps, peristaltic pumps, or servo-driven systems. Nozzles center the ampoule neck for accurate filling, with volumes adjustable from 0.5ml to 25ml in a single dose.
- Post-Nitrogen Flushing(optional): Additional nitrogen is injected post-filling to further ensure sterility.
- Sealing: Ampoules are sealed using combustible gases (e.g., oxygen and LPG) to melt the glass neck, forming an airtight seal. Pre-warming and rotation units ensure perfect sealing without glass damage.
- Collection: Sealed ampoules are collected in trays or discharged for inspection and labeling.

Technical Specification of Injection Ampoule Filling Machine

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 Injection Ampoule Filling Machine

Precision and Accuracy: Ensures exact dosing, minimizing over/under-dosing and material wastage.

Sterility: Automated processes and nitrogen flushing reduce contamination risks, critical for injectables.

High Output: Multi-head configurations (2, 4, 8, or 16 heads) enable high-speed production to meet large-scale demands.

Versatility: Suitable for various industries (pharmaceutical, biotech, cosmetics, chemicals) and liquid types (aqueous, viscous, or powders).

Ease of Use: User-friendly interfaces and minimal training requirements, with detailed documentation provided by manufacturers.

Durability: Stainless steel construction ensures long-term reliability and compliance with regulatory standards.

Flexibility: Tool-less changeovers and adjustable filling volumes accommodate diverse ampoule sizes and production needs.

Safety: Automated sealing with combustible gases is managed with safety valves and cooling systems to prevent overheating.

Key Features of Injection Ampoule Filling Machine

Construction: Built with stainless steel 316L for contact parts and stainless steel 304 for non-contact parts, ensuring durability, corrosion resistance, and compliance with cGMP. The machine often features a matt finish for aesthetic appeal and ease of cleaning.

Filling Systems: Offers flexibility with multiple filling options:
- Piston Pumps: Volumetric filling for high precision (±1% accuracy).
- Peristaltic Pumps: Ideal for sterile, contamination-free filling.
- Servo-Driven Systems: Allow touch-screen volume adjustments for enhanced precision and automation.
- Output Capacity: Varies by model:
  - Single-head machines: ~1,500 ampoules/hour (lab-scale).
  - Four-head machines: ~6,000–7,200 ampoules/hour (medium-scale).
  - Eight-head machines: Up to 12,000–28,000 ampoules/hour (high-speed production).

Automation: Fully automatic models minimize human intervention, featuring PLC systems and touch-screen HMIs for real-time parameter control, error detection, and fill volume adjustments. Semi-automatic or manual models are available for smaller operations.

Ampoule Compatibility: Handles open-mouth (Type B/C) and closed-mouth (Type D) ampoules, with tool-less changeover for sizes from 1ml to 30ml.

Sterility Features: Includes nitrogen flushing, laminar flow compatibility, and isolator systems to maintain Class 100 sterile conditions.

Safety and Maintenance: Equipped with safety valves, pressure reducers, and stainless steel hoods to channel fumes during sealing. Large bottom openings and tool-less format changes ensure easy cleaning and maintenance.

Additional Features:
- Pre-warming stations for perfect sealing.
- No-ampoule-no-fill sensors to prevent wastage.
- Waste tip collectors for clean operation.
- Optional integration with washing, sterilization tunnels, inspection, and labeling systems for a complete production line.

FAQ for Injection Ampoule Filling Machine

What is an Injection Ampoule Filling Machine?

The Injection Ampoule Filling Machine is a fully automatic monobloc system designed for high-precision filling and flame sealing of sterile liquid injectables into glass ampoules. It handles free-flowing to viscous liquids in ampoules ranging from 1ml to 30ml. The machine integrates nitrogen flushing (before, during, and after filling), precise piston pump filling, neck pre-heating, and LPG + Oxygen flame sealing in one compact unit. It is built as per cGMP, USFDA, WHO, and ISO 9187-1:2010 standards, making it ideal for pharmaceutical parenteral production.

What models are available and what is their production capacity?

We offer four standard models:

AFS-1 (Single Head): Up to 25 ampoules per minute (~1,500 per hour)
AFS-2 (Two Heads): Up to 50 ampoules per minute
AFS-4 (Four Heads): Up to 100 ampoules per minute (~6,000 per hour)
AFS-8 (Eight Heads): Up to 200 ampoules per minute (~12,000 per hour)

Custom high-speed models are available up to 36,000 ampoules per hour. Filling range is 0.5ml to 25ml with ±1% accuracy. Ampoule size compatibility: 1ml–30ml (AFS-1) and 1ml–20ml (higher models).

How does the Injection Ampoule Filling Machine work?

The machine operates on the slant traveling principle, which gently handles ampoules and reduces glass breakage and particle contamination. The process includes:

Automatic loading of sterilized ampoules from the hopper
Nitrogen pre-flushing to remove oxygen
Precise volumetric filling using piston pumps with neck centering
Nitrogen post-flushing
Neck pre-warming
Flame sealing with LPG + Oxygen burners

It features a “No Ampoule – No Filling” system and automatic collection of sealed ampoules. The slant design and automated steps ensure high sterility and minimal human intervention.

What are the key features of the Injection Ampoule Filling Machine?

Key features include:

- Nitrogen flushing before, during, and after filling to prevent oxidation
- SS 316L product contact parts and SS 304 non-contact parts
- Tool-less quick changeover with minimal parts
- Ampoule neck centering during flushing and filling
- Pre-warming station and flame flow meters for perfect sealing
- “No Ampoule – No Fill/Seal” safety system
- Compatibility with laminar airflow and isolator systems
- Optional PLC/HMI and SCADA for advanced control
- Easy cleaning, low maintenance, and full cGMP compliance

Which industries use the Injection Ampoule Filling Machine and what are its main benefits?

It is widely used in:

Pharmaceuticals (injectables, vaccines, and parenterals)
Biotechnology
Veterinary medicines
Cosmetics
Chemical and agro-insecticide industries

Main benefits:

Excellent filling accuracy (±1%) with very low product wastage
Reduced risk of contamination and glass particles due to slant design
Fast format changeover and easy validation
Compact footprint with high output
Enhanced sterility through automation and nitrogen flushing
Robust, durable construction with easy maintenance

Countries We Export to

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