Onion Skin Ampoule Filling Machine

Q: What models and production capacities are available for the Onion Skin Ampoule Filling Machine?

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) Higher custom models can reach up to 36,000 ampoules per hour. It supports ampoule sizes from 1ml to 30ml (model dependent), with filling range 0.5ml to 25ml (or smaller volumes down to 0.1ml in special configurations) and filling accuracy of ±1% .

Q: How does the Onion Skin Ampoule Filling Machine handle delicate thin-walled ampoules?

The machine uses the slant traveling principle along with neck centering and ampoule rotation to gently handle fragile onion skin ampoules and reduce breakage. Key adaptations include: Specially designed burners for thin glass Pre-warming station for uniform heating Nitrogen flushing before, during, and after filling Precise neck centering during flushing and filling Sterilized ampoules move through synchronized star wheels for pre-gassing, filling with piston pumps, post-gassing, pre-heating, and LPG + Oxygen flame sealing. A “ No Ampoule – No Filling ” system prevents wastage.

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

Key features include: All product contact parts in SS 316L and non-contact parts in SS 304 Nitrogen flushing before, during, and after filling to prevent oxidation Tool-less quick changeover with minimal parts Slant design and neck centering to accommodate variations in thin ampoule shape and thickness Pre-warming station and precise flame control “No Ampoule – No Fill/Seal” safety system Compact monobloc design with easy maintenance and cleanroom compatibility Optional PLC/HMI with 21 CFR Part 11 compliance These features ensure high sterility, low glass breakage, and consistent sealing quality.

Description

Onion Skin Ampoule Filling Machine is a specialized piece of equipment designed for filling and sealing thin-walled, crushable glass ampoules, often referred to as “onion skin” ampoules due to their delicate, thin glass structure (typically 0.3mm to 0.8mm thick). These machines are widely used in pharmaceutical, biotech, cosmetic, veterinary, and chemical industries for precise filling and sealing of small-volume liquid products, such as medicines, serums, vaccines, agro-insecticides, and biological indicators. Below is a detailed description of the machine’s features, operation, and specifications based on available information:

- Tool-Less Changeover: Minimal parts needed for switching between ampoule sizes (1ml to 20ml), enhancing productivity.
- Safety and Maintenance: Pendant-type electrical control panel for ease of operation and safety. Large bottom opening for easy cleaning and maintenance.
- Customization: Available in standard and custom models to meet specific industry requirements, including biological indicator tubes.
- Certifications: CE-certified and compliant with cGMP and FDA standards for aseptic manufacturing.
- Eco-Friendly Option: Some models use oxyhydrogen gas generators (HHO technology) instead of traditional gas cylinders, reducing explosion risks and operational costs.

Salient Features of Onion Skin Ampoule Filling Machine

Compact model.
All contact parts made from High Quality Stainless Steel 316L & Non-contact parts made from Stainless Steel 304.
Machine equipped with pre-warming station.
Full accessibility allows easy maintenance.

“No Ampoule – No Filling” system.
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 Onion Skin Ampoule Filling Machine

The sterilized ampoule tray directly loaded in to slant hopper of the unit. The Synchronized star wheel delivers ampoules, one by one on moving eccentric ampoule rack in single/double/four/six/eight. During the movement of ampoule machine perform below mentioned operations:

Pre-gassing with Nitrogen
Filling the product
Post Gassing with Nitrogen
Pre-heating with LPG & Oxygen combination
Sealing with LPG & Oxygen combination

At the end duly filled and sealed ampoules get collected automatically onto collection tray of the machine. Ampoules now can be collected for further inspection and/or sticker labeling operations.

Technical Specification of Onion Skin 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 Onion Skin Ampoule Filling Machine

High Precision: Ensures accurate dosing (±1% or better) for small volumes.

Sterility: Sealed environment and gas flushing prevent contamination.

Versatility: Handles a wide range of ampoule sizes and liquid viscosities (free-flowing to heavy oils).

Efficiency: High output and tool-less changeover reduce downtime.

Reliability: Robust stainless steel construction ensures durability and low maintenance.

Key Features of Onion Skin Ampoule Filling Machine

Design and Construction:
- Material: Built with high-quality stainless steel, with contact parts made of AISI SS 316L and non-contact parts of AISI SS 304, ensuring compliance with cGMP (Current Good Manufacturing Practices) and FDA standards for sterile and hygienic operations.
- Frame: Stainless steel square pipe frame with a matt finish, designed for durability and ease of cleaning. A large opening at the bottom facilitates maintenance.
- Compact Design: Monobloc design integrates filling and sealing operations on a single platform, reducing contamination risks and ensuring cleanroom compatibility.

Filling and Sealing Mechanism:
- Filling Principle: Operates on volumetric piston pumps or peristaltic pumps for high precision (up to ±1% accuracy), capable of filling volumes from 0.2ml to 25ml in a single dose.
- Sealing Process: Uses oxyhydrogen flame (generated from water electrolysis) or traditional oxygen and LPG (propane) for sealing, with specially designed burners suited for thin glass (0.3mm to 0.8mm). The oxyhydrogen flame reaches temperatures up to 2800°C for fast, high-quality sealing.
- Pre-Warming Station: Includes a pre-warming unit to heat ampoules before sealing, ensuring a secure and uniform seal.
- Gas Flushing: Offers nitrogen or argon flushing before and after filling to protect sensitive products from oxidation or contamination.

Ampoule Handling:
- Size Compatibility: Handles ampoules with a minimum diameter of 6mm to 7mm and a minimum height of 55mm, with no upper limit for diameter or height (customizable). Suitable for 1ml to 30ml ampoules with minimal changeover parts.
- Slant Travel Principle: Ampoules travel at an angle during filling and sealing to accommodate variations in neck dimensions, thickness, and ovality, ensuring consistent performance.
- Neck Centering: Precise centering of ampoule necks during pre-heating, post-heating, gas flushing, and filling operations to ensure accuracy and avoid breakage.
- Rotation: Ampoules are rotated during pre-warming and sealing to achieve uniform heating and sealing.

Operation Process:
- Infeed and Loading: Sterilized ampoules are loaded into a slant hopper, then fed one by one via a synchronized star wheel onto an eccentric moving rack in single, double, four, six, or eight units per stroke, depending on the machine model.
- Sequential Operations:
  - Pre-Gassing: Nitrogen or argon is flushed to purge air from the ampoule.
  - Filling: Liquid is dispensed with high precision using piston or peristaltic pumps.
  - Post-Gassing: Additional gas flushing to protect the filled product.
  - Pre-Heating: Low-pressure flame warms the ampoule neck for sealing.
  - Sealing: High-temperature flame seals the ampoule, with specially designed rollers rotating the ampoule for a uniform seal.
- Collection: Filled and sealed ampoules are automatically discharged onto a collection tray (often with a “dead tray” for upright placement) without human contact, minimizing contamination.

Production Capacity:
- Output ranges from 10 to 250 ampoules per minute, depending on the model (single-head, double-head, four-head, six-head, or eight-head). For example:
  - Single-head: ~25–50 ampoules/min (lab-scale).
  - Four-head: ~100–150 ampoules/min (medium-scale).
  - Eight-head: Up to 300 ampoules/min (high-speed production).
- Specific case: The FPS1-OS-SS model fills 6.7mm x 60mm onion skin tubes with 0.1ml to 0.4ml at 45–50 ampoules/min with ±0.5% accuracy.

Additional Features:
- Tool-Less Changeover: Minimal parts needed for switching between ampoule sizes (1ml to 20ml), enhancing productivity.
- Safety and Maintenance: Pendant-type electrical control panel for ease of operation and safety. Large bottom opening for easy cleaning and maintenance.
- Customization: Available in standard and custom models to meet specific industry requirements, including biological indicator tubes.
- Certifications: CE-certified and compliant with cGMP and FDA standards for aseptic manufacturing.
- Eco-Friendly Option: Some models use oxyhydrogen gas generators (HHO technology) instead of traditional gas cylinders, reducing explosion risks and operational costs.

FAQ for Onion Skin Ampoule Filling Machine

What is an Onion Skin Ampoule Filling Machine?

An Onion Skin Ampoule Filling Machine is a specialized automatic monobloc system designed for filling and flame sealing thin-walled, delicate “onion skin” glass ampoules (glass thickness 0.3mm to 0.8mm). These crushable ampoules are commonly used for small-volume sterile liquids such as injectables, vaccines, serums, biological indicators, and agro-insecticides. The machine integrates nitrogen flushing, precise volumetric filling, pre-warming, and sealing while handling the fragility of thin glass with minimal breakage.

What models and production capacities are available for the Onion Skin Ampoule Filling Machine?

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)

Higher custom models can reach up to 36,000 ampoules per hour. It supports ampoule sizes from 1ml to 30ml (model dependent), with filling range 0.5ml to 25ml (or smaller volumes down to 0.1ml in special configurations) and filling accuracy of ±1%.

How does the Onion Skin Ampoule Filling Machine handle delicate thin-walled ampoules?

The machine uses the slant traveling principle along with neck centering and ampoule rotation to gently handle fragile onion skin ampoules and reduce breakage. Key adaptations include:

Specially designed burners for thin glass
Pre-warming station for uniform heating
Nitrogen flushing before, during, and after filling
Precise neck centering during flushing and filling

Sterilized ampoules move through synchronized star wheels for pre-gassing, filling with piston pumps, post-gassing, pre-heating, and LPG + Oxygen flame sealing. A “No Ampoule – No Filling” system prevents wastage.

What are the key features of the Onion Skin Ampoule Filling Machine?

Key features include:

All product contact parts in SS 316L and non-contact parts in SS 304
Nitrogen flushing before, during, and after filling to prevent oxidation
Tool-less quick changeover with minimal parts
Slant design and neck centering to accommodate variations in thin ampoule shape and thickness
Pre-warming station and precise flame control
“No Ampoule – No Fill/Seal” safety system
Compact monobloc design with easy maintenance and cleanroom compatibility
Optional PLC/HMI with 21 CFR Part 11 compliance

These features ensure high sterility, low glass breakage, and consistent sealing quality.

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

It is widely used in:

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

Main benefits:

Gentle handling of delicate thin-walled ampoules with reduced breakage
High filling accuracy (±1%) and minimal product wastage
Enhanced sterility through nitrogen flushing and automation
Fast format changeover and low maintenance
Compact footprint with robust cGMP, USFDA, WHO, and ISO-compliant design
Easy integration into complete injectable production lines

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Onion Skin Ampoule Filling Machine

Description

Salient Features of Onion Skin Ampoule Filling Machine

Working Principle of Onion Skin Ampoule Filling Machine

Technical Specification of Onion Skin Ampoule Filling Machine

Types of Ampoule Filling Machine

Applications of Ampoule Filling Machine

Advantages of Onion Skin Ampoule Filling Machine

High Precision: Ensures accurate dosing (±1% or better) for small volumes.

Sterility: Sealed environment and gas flushing prevent contamination.

Versatility: Handles a wide range of ampoule sizes and liquid viscosities (free-flowing to heavy oils).

Efficiency: High output and tool-less changeover reduce downtime.

Reliability: Robust stainless steel construction ensures durability and low maintenance.

Key Features of Onion Skin Ampoule Filling Machine

FAQ for Onion Skin Ampoule Filling Machine

Countries We Export to

Partner with Industry Experts

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