Six Needle Ampoule Filling Machine

Q: How does the Six Needle Ampoule Filling Machine work?

The machine operates on the slant traveling principle for gentle ampoule handling and reduced glass breakage. The automated process includes: Automatic loading of sterilized ampoules from the hopper Nitrogen pre-flushing to remove oxygen Simultaneous filling through six needles with neck centering Nitrogen post-flushing Neck pre-warming Accurate flame sealing using LPG + Oxygen burners It features “No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems to prevent wastage and ensure maximum sterility.

Description

Six Needle Ampoule Filling Machine is an advanced, automated pharmaceutical device designed for high-speed, precise filling and sealing of glass ampoules, commonly used for injectable drugs, vaccines, serums, and other sterile liquids. Below is a detailed description based on industry standards and available information: The Six Needle Ampoule Filling Machine, also referred to as a Six Head Ampoule Filling and Sealing Machine, is a compact, high-efficiency piece of equipment built for pharmaceutical, biotech, cosmetic, and chemical industries. It is designed to handle medium to large-scale production, filling and sealing glass ampoules with volumes typically ranging from 1 ml to 25 ml in a single dose. The machine operates on the principle of slant travel of ampoules to accommodate variations in neck dimensions, thickness, and ovality, ensuring precise and consistent filling and sealing.

Loading: Sterilized ampoules are loaded into the slant hopper and fed onto a wire mesh conveyor or receiving rack via a star wheel.
Pre-Gassing: Nitrogen is flushed into ampoules to create an inert environment.
Filling: Six needles dispense a preset volume of liquid (or powder) with high accuracy, aided by neck centering to prevent spillage.
Post-Gassing: A second nitrogen flush ensures sterility post-filling.
Pre-Warming: A low-pressure flame warms ampoules to prepare for sealing, removing residual droplets.
Sealing: Rollers rotate ampoules while a high-pressure flame (oxygen + LPG) seals them, ensuring airtight closure.
Collection: Sealed ampoules are automatically collected in an upright position on a tray for further processing (e.g., labeling or inspection).

This description provides a comprehensive overview of a Six Needle Ampoule Filling Machine, covering its design, operation, and applications, based on industry-standard features and sourced information. If you need a visual chart or further customization details, please let me know!

Salient Features of Six Needle Ampoule Filling Machine

Compact cGMP model.
Higher output up to 9000 Ampoules per hour.
Full accessibility allows easy maintenance.
Flow Meters for regulating flames easily.
“No Ampoule – No Filling” system.
Machine equipped with pre-warming station.

Ampoule neck centering during gas flushing and filling operations.
Possibility of nitrogen gas flushing before, during and after filling.
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.
Minimum change over time, little maintenance, easy cleaning.

Working Principle of Six Needle 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 six 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.

Technical Specification of Six Needle Ampoule Filling Machine

Model Name	AFS-6
Production Speed	Up to 150 ampules/minute
Ampoule Sizes	1 ml to 20 ml
Filling Error	± 1%
Sealing Gas	LPG and Oxygen (O₂)
Nitrogen Gas	Pre & Post Nitrogen
Power Load	2 H. P.
Power Voltage	230 Volts, Single Phase, 50 Hertz
Contact Parts	Made from Stainless Steel 316L
Non-Contact Parts	Made from Stainless Steel 304
Machine Size	2000mm (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

Benefits of Six Needle Ampoule Filling Machine

High output with minimal labor due to automation.

Precise filling and sealing, reducing product wastage.

Robust, hygienic design compliant with cGMP standards.

Flexible for various ampoule sizes and product types.

Low maintenance with easy cleaning and tool-less changeovers.

Key Features of Six Needle Ampoule Filling Machine

Six Filling Heads: Equipped with six precision needles for simultaneous filling, enabling higher throughput compared to single or dual-head machines. Output ranges from 80 to 280 ampoules per minute, depending on ampoule size (e.g., 120–150 ampoules/min for 1 ml, 80–100 ampoules/min for 10 ml).

Construction: Built with a robust stainless steel (SS 316L for contact parts, SS 304 for non-contact parts) square pipe frame and matt-finished coverings, meeting cGMP standards for hygiene and durability. A large bottom opening facilitates easy cleaning and maintenance.

Filling Mechanism: Utilizes volumetric piston pumps or optional peristaltic pumps for accurate dosing (0.5 ml to 25 ml). Features a “No Ampoule, No Filling” system to minimize wastage by ensuring liquid is dispensed only when an ampoule is present.

Nitrogen Flushing: Includes pre- and post-nitrogen purging stations to flush inert gas, reducing oxidation and contamination, ensuring product sterility.

Sealing Process: Incorporates a pre-warming station with a low-pressure flame to prepare ampoules for sealing, followed by a sealing unit using oxygen and LPG (propane). Specially designed rollers rotate ampoules for uniform, 360-degree sealing.

Automation and Control: Features a pendant-type electrical control panel for ease of operation and safety. PLC systems allow real-time parameter adjustments and error monitoring. Flow meters regulate flames, and an efficient cooling system prevents overheating.

Ampoule Handling: Ampoules are loaded via a slant hopper and transferred by a synchronized star wheel to an eccentric rack, moving in groups of six. The rack’s slant travel ensures precise positioning during pre-gassing, filling, post-gassing, pre-heating, and sealing. Filled and sealed ampoules are collected upright in a tray for further processing.

Versatility: Suitable for open-mouth and closed-mouth ampoules (Type B and C). Can handle liquids, powders, or pellets, with applications in pharmaceuticals, cosmetics, and agrochemicals.

Output Capacity: Typically achieves 6,000 to 12,000 ampoules per hour, depending on size and configuration, making it ideal for medium to large-scale production.

Safety and Efficiency: Includes safety valves, pressure reducers, and a stainless steel hood to channel fumes during sealing. Minimal changeover time for different ampoule sizes (1 ml to 10 ml) with tool-less format changes.

FAQ for Six Needle Ampoule Filling Machine

What is a Six Needle Ampoule Filling Machine?

A Six Needle Ampoule Filling Machine (also known as Six Head Ampoule Filler Sealer) is a fully automatic monobloc machine designed for high-speed filling and flame sealing of sterile liquid injectables into glass ampoules. It uses six filling needles working simultaneously and integrates nitrogen flushing (pre- and post-filling), precise volumetric piston filling, neck pre-heating, and LPG + Oxygen flame sealing in one compact unit. This model is ideal for large-scale pharmaceutical production and fully complies with cGMP, USFDA, WHO, and international regulatory standards.

What is the production capacity of the Six Needle Ampoule Filling Machine?

The Six Needle Ampoule Filling Machine offers a production capacity of up to 150 ampoules per minute (approximately 9,000 ampoules per hour). It supports ampoule sizes from 1ml to 20ml with a filling range of 0.5ml to 25ml and maintains excellent filling accuracy of ±1%. This makes it suitable for high-volume sterile injectable manufacturing.

How does the Six Needle Ampoule Filling Machine work?

The machine operates on the slant traveling principle for gentle ampoule handling and reduced glass breakage. The automated process includes:

Automatic loading of sterilized ampoules from the hopper
Nitrogen pre-flushing to remove oxygen
Simultaneous filling through six needles with neck centering
Nitrogen post-flushing
Neck pre-warming
Accurate flame sealing using LPG + Oxygen burners

It features “No Ampoule – No Filling” and “No Ampoule – No Seal” safety systems to prevent wastage and ensure maximum sterility.

What are the key features of the Six Needle Ampoule Filling Machine?

Key features include:

Six needle / six head monobloc design for higher productivity
Nitrogen flushing before, during, and after filling
Precision piston pumps for accurate dosing
Tool-less quick changeover with minimal parts
All product contact parts made of SS 316L
Slant design for smooth movement and low glass particle generation
Pre-heating station and precise flame control with flow meters
Compact footprint with easy cleaning and maintenance
Optional PLC/HMI with SCADA compatibility

What are the main benefits of the Six Needle Ampoule Filling Machine?

Main benefits include:

High production speed of up to 150 ampoules per minute
Excellent filling accuracy (±1%) with minimal product wastage
Gentle handling that reduces glass breakage and contamination risk
Ideal for large-scale batch production
Fast format changeover and easy validation
Compact design suitable for cleanroom environments
Full cGMP compliance and reliable high-performance operation

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