Lab Scale Ampoule Filler

Q: Who should use a Lab Scale Ampoule Filler and what are its main benefits?

This machine is perfect for pharmaceutical R&D , pilot-scale production, biotechnology labs, veterinary medicine development, cosmetic injectable manufacturing, and small chemical batches. Main benefits include: Compact footprint and low power consumption (0.5 H.P.) High precision with minimal product wastage Quick changeover and easy cleaning/maintenance Superior sterility through nitrogen flushing and immediate sealing Cost-effective for small to medium batches Easy integration into lab environments with optional IQ/OQ documentation It offers an excellent entry point into automated sterile filling without the high investment of larger production machines.

Description

Lab Scale Ampoule Filler is a compact, specialized machine designed for small-scale filling and sealing of glass ampoules, primarily used in R&D laboratories, small pharmaceutical companies, and pilot batch production. It is built to handle sterile injectable preparations, cosmetics, agro-insecticides, veterinary medicines, and other chemicals, ensuring precision and compliance with cGMP standards. Below is a detailed description based on available information:

Built on the proven slant-travel design, this lab scale ampoule filler ensures gentle handling of ampoules, minimal breakage, and superior sterility. It integrates pre-gassing, volumetric filling, post-gassing, neck pre-heating, and high-precision flame sealing in one compact cGMP-compliant unit.

Loading: Empty, washed, and sterilized ampoules are loaded into the hopper and transferred to a transport rack via a star wheel or cassette.

Nitrogen Purging: Ampoules pass through a pre-nitrogen flushing station to remove air.

Filling: Precise liquid filling occurs via volumetric piston pumps or other configured mechanisms.

Post-Nitrogen Flushing: Additional nitrogen flushing prevents contamination.

Pre-Warming: Ampoules are warmed at a low-pressure flame station to prepare for sealing.

Sealing: Rollers rotate ampoules at the sealing station, where oxygen and LPG flames seal the necks.

Collection: Filled and sealed ampoules are collected upright in a tray for further processing.

Salient Features of Lab Scale Ampoule Filler

Class 100 Laminar Air Flow can be installed optionally.
PLC system with Graphical User Interface in special models.
Monobloc design with filling and sealing units combined.
Different filling mechanism models available.
Contact Area parts suitable for Autoclaving / Sterilization.

Small footprint equipment.
Acceptable error range of ± 1%.
Frequency drive unit for speed variation.
IQ/OQ validation protocols on demand.
1ml-30ml ampoule size suitability.
Safety guards with guide railing on demand.

Working Principle of Lab Scale Ampoule Filler

Machine having hopper for storing ampoules. User has to load empty ampoules on this hopper in bulk from where ampoule deliver onto moving rack one by one. In the movement over rack ampoule reaches to the filling station where filling needles fill preset volume of liquid in ampoules. Further ampoules reached to the sealing station where two burner nozzles installed in which first one is preheating nozzle and second is sealing nozzle. Rollers provided for rotation of ampoules, so evenly heating provided on all around the ampoule neck. During rotation of ampoule with nozzle gassing, the glass of ampoule get melt. Sealing clipper installed which do up & down movement above sealing unit. During down movement clipper take off excess melt part of ampoules and drop into waste glass collection box. Duly filled and packed ampoules get collected onto delivery tray of the machine.

Technical Specification of Lab Scale Ampoule Filler

Model	AFS-30
Production Output	Up to 25 ampules/minute
Ampoule Size	1ml to 30ml
Filling Accuracy	± 1%
Require Gas for Sealing	LPG & Oxygen (O₂)
Nitrogen Flushing	Pre & Post Nitrogen Flushing Available
Power Specification	0.5 H. P.
Electrical Characteristics	230 Volts, Single Phase, 50 Hertz
Contact Parts	Made from Stainless Steel 316L.
Non-Contact Parts	Made from Stainless Steel 304
Overall Dimension	915mm (L) x 610mm (W) x 965mm (H) approx.
Net Weight	150 Kgs. approx.
Gross Weight	225 Kgs. 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 Lab Scale Ampoule Filler

High Precision: Ensures accurate filling with minimal product waste.

Minimal Change-Over: Quick adjustments for different ampoule sizes reduce downtime.

Automation: Reduces human intervention, improving consistency and reducing contamination risks.

Compact and Cost-Effective: Designed for low-budget, small-scale operations with low maintenance needs.

Versatility: Handles a wide range of ampoule sizes and liquid types, including pharmaceuticals and chemicals.

Key Features of Lab Scale Ampoule Filler

Construction: Made from high-quality stainless steel 316L for contact parts and stainless steel 304 for non-contact parts, ensuring durability, corrosion resistance, and compliance with cGMP requirements.

Capacity: Suitable for filling ampoules ranging from 1ml to 30ml, with a filling capacity of 0.5ml to 25ml in a single dose. The machine can process 10 to 250 ampoules per minute, with single-head models producing up to 1800 ampoules per hour.

Filling Mechanism: Operates on a volumetric piston-pump system for precise liquid filling. Some models offer configurable filling mechanisms, such as peristaltic pumps or servo-driven systems, depending on user requirements.

Nitrogen Flushing: Equipped with pre- and post-nitrogen flushing units to remove atmospheric air and prevent contamination, ensuring product stability.

Sealing Process: Features a pre-warming station with low-pressure flames to warm ampoules, followed by a sealing station using oxygen and LPG (propane) for precise sealing. Specially designed rollers rotate ampoules during sealing for uniform closure.

Ampoule Handling:
- Ampoules are loaded via an in-feed hopper and transferred to a traveling rack or star wheel in formats of one, two, four, or eight, depending on the model.
- Neck centering ensures accurate filling and sealing, with minimal change-over time between ampoule sizes.

Design: Compact, monobloc design integrates filling and sealing on a single platform, reducing footprint and simplifying operation. Some models include a dead-tray for upright collection of filled and sealed ampoules, minimizing manual handling.

Additional Features:
- Pre-heating unit for thick glass ampoules to ensure proper sealing.
- Flow meters for flame regulation and an efficient cooling system to prevent overheating, enhancing machine longevity.
- Safety features like stainless steel hoods to channel fumes and safety valves for gas circuits.

Applications: Ideal for small-scale production, laboratory testing, and pilot batches in pharmaceutical, biotech, cosmetic, and chemical industries. Suitable for filling type B and C open-mouth ampoules.

FAQ for Lab Scale Ampoule Filler

What is a Lab Scale Ampoule Filler?

A Lab Scale Ampoule Filler (Model AFS-30) is a compact, fully automatic single-head machine designed for small-scale sterile filling and flame sealing of injectable liquids into glass ampoules. It is ideal for R&D laboratories, pilot batch production, and small pharmaceutical or biotech companies. The machine integrates pre-gassing, volumetric filling, post-gassing, neck pre-heating, and sealing in a monobloc cGMP-compliant design with slant ampoule travel for gentle handling and minimal breakage.

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

The Lab Scale Ampoule Filler (AFS-30) has a production output of up to 25 ampoules per minute (approximately 1,500 ampoules per hour). It supports ampoule sizes from 1 ml to 30 ml with a filling volume range of 0.5 ml to 25 ml per dose. The machine delivers a filling accuracy of ±1% using a volumetric piston pump and is suitable for both Type B and Type C open-mouth ampoules.

What key features ensure sterility and accuracy in the Lab Scale Ampoule Filler?

Key features include:

Nitrogen pre-gassing and post-gassing with ampoule neck centering
“No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems
Pre-heating station for perfect flame sealing (LPG + Oxygen or oxy-hydrogen)
All product contact parts made of SS 316L and non-contact parts of SS 304
Frequency drive for variable speed control
Flow meters for precise flame regulation
Optional Class 100 Laminar Air Flow and PLC with GUI

These features ensure high sterility, minimal wastage, and full cGMP compliance.

How does the Lab Scale Ampoule Filler work?

Sterilized ampoules are loaded into the infeed hopper and automatically transferred via a starwheel to a moving rack in a slanted position. As the ampoules travel forward, the machine performs the following steps sequentially:

Pre-gassing with nitrogen
Precise volumetric liquid filling
Post-gassing
Neck pre-heating
High-speed rotation and flame sealing (with sealing clipper to remove excess glass)

Filled and sealed ampoules are then collected upright in a delivery tray. The compact design and slant movement reduce breakage and contamination risks.

Who should use a Lab Scale Ampoule Filler and what are its main benefits?

This machine is perfect for pharmaceutical R&D, pilot-scale production, biotechnology labs, veterinary medicine development, cosmetic injectable manufacturing, and small chemical batches.

Main benefits include:

Compact footprint and low power consumption (0.5 H.P.)
High precision with minimal product wastage
Quick changeover and easy cleaning/maintenance
Superior sterility through nitrogen flushing and immediate sealing
Cost-effective for small to medium batches
Easy integration into lab environments with optional IQ/OQ documentation

It offers an excellent entry point into automated sterile filling without the high investment of larger production machines.

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