Lab Scale Ampoule Filler

A 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:

Lab Scale Ampoule Filler Video

Key Features:

• 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.

Operation Process:

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

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

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

4. Post-Nitrogen Flushing: Additional nitrogen flushing prevents contamination.

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

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

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

Advantages:

• 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.

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 Lab Scale Ampoule Filler

• Small footprint equipment.
• 1ml-30ml ampoule size suitability.
• Monobloc design with filling and sealing units combined.
• Different filling mechanism models available.
• Acceptable error range of ± 1%.
• Safety guards with guide railing on demand.
• Class 100 Laminar Air Flow can be installed optionally.
• Contact Area parts suitable for Autoclaving / Sterilization.
• Frequency drive unit for speed variation.
• IQ/OQ validation protocols on demand.
• PLC system with Graphical User Interface in special models.

Process Operation 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

* 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.