An Automatic Powder Filling Bunging Machine also known as an Injectable Dry Powder Filling and Stoppering Machine is a specialized automated equipment primarily used in the pharmaceutical industry for the precise filling of sterile dry powders into vials or bottles, followed by the application of rubber stoppers. This machine ensures high accuracy, sterility, and efficiency, reducing manual labor and contamination risks. It is compact, GMP-compliant, and often integrated into aseptic production lines with features like laminar airflow and isolators.
These machines are essential for handling micro-doses of powders with uniform density, achieving volumetric accuracy of ±1-2%, and supporting both half and full bunging for various vial sizes. While primarily pharmaceutical, similar auger-based variants are used in food, cosmetics, and chemical sectors for filling powders like spices, proteins, or chemicals.
Automatic Powder Filling Bunging Machine Video
Key Features
Automatic powder filling bunging machines are designed for reliability and ease of use. Here are the main features based on standard models:
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FeatureDescription: Compact DesignBuilt on a sturdy frame with minimal footprint; includes turntables, slat conveyor belts, and access doors for easy servicing.
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Precision Filling Mechanism: Uses a powder wheel or auger with adjustable pistons or screws for exact dosing; supports multidose filling without part changes.
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Bunging/Stoppering Unit: Integrated rubber stopper applicator for full/half insertion; handles dry/wet stoppers; individual drives for filling and sealing to synchronize speeds.
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Safety & Automation: No-vial/no-stopper detection; digital counters for production tracking; PLC/HMI touch screens for easy setup; compatible with 21 CFR, RABS, and isolators.
Working Principle
The machine operates in a continuous, automated cycle under laminar flow to maintain sterility. Here’s how it typically works:
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Vial Feeding: Sterile vials enter via a turntable or conveyor from a washing/tunnel system and are positioned on a star wheel or indexing plate .
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Powder Dosing: Powder from a hopper is agitated and fed into a secondary hopper via vacuum. An auger screw or powder wheel rotates to measure and dispense the exact volume into each vial. Servo systems ensure repeatability.
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Bunging/Stoppering: Filled vials move to the stoppering station, where rubber bungs are picked and pressed using pneumatic or mechanical presses. The system checks for proper placement.
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Ejection & Inspection: Vials are ejected onto an output conveyor. Optional check-weighers or vision systems verify fill levels and seals.
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Safety Halt: If a vial is missing or misaligned, sensors trigger an immediate stop to prevent waste or errors.
The entire process is controlled by PLC for seamless operation, with minimal human intervention.
Benefits
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Efficiency: High-speed output with low downtime; quick format changes.
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Accuracy & Safety: Ensures precise dosing to meet regulatory standards; reduces powder dust and cross-contamination.
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Cost-Effective: Compact size saves space; stainless steel construction ensures longevity and easy validation.
Application of Powder Filling Bunging Machine
There are different types of powder filling machines available for each individual operation. Auger Filler is having below industry wise applications:
Pharmaceutical Industry: Dry Syrup Powder and API Powder.
Herbal & Nutraceutical Industry: Moringa powder, leaves powder, protein powder, baking soda etc.
Food Industry: Milk powder, spices, pulses, fine flour, powdered sugar, coffee powder, tea powder, salt, food color, food flavor, curry powder, flour, cornstarch, baking mix, cocoa, glazing compound, psyllium husk, oregano, instant coffee, coffee beans, salt, bread, sugar, sand etc.
Cosmetic Industry: Face pack powder, talcum powder, translucent powders, color cosmetics, hair care powder etc.
Chemical Industry: Ceramic powder, acid powders, specialty chemicals etc.
Agriculture Industry: Fertilizers, Insecticides, NPK granules, powdered organics, inorganic fertilizers etc.
Salient Features of Powder Filling Machine
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Standard as well as Optional Servo Driven Filling Head.
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Multiple auger head system as per customer requirements.
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“No Bottle – No Fill” System.
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All contact parts made of SS316 and Nylon/HDPE material with easy removal system for Cleaning.
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Machine construction in SS304 material.
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Filling Accuracy of +/- 3% depending upon powder characteristics and environmental conditions.
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A.C. Variable Frequency Drive Speed Control
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Built in Turn Tables with Separate Drive for speed control.
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IQ/OQ documentation can be provided.
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PLC system with Graphical User Interface can be offered.
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Inbuilt Laminar Air Flow can be offered for sterile class 100 filling.
Process Operation of Auger Powder Filler Machine
Duly cleaned containers are placed to the filling machine platform. From there containers transport towards the filling station with the help of conveyor belt. As soon as the bottle is sensed by bottle sensor, magnetic clutch starts to rotate which is mounted on the auger shaft. It fills the desired volume of powder to the container through Auger. After completion of filling process bottle transfers on conveyor for next capping operations.
Design of Powder Filling Bunging Machine
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Drive Assembly: Consist motor, transmission and the switching mechanism to start and stop machine.
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Hopper: It stored the material as a quarantine before filling. Through tooling it discharge material onto filling station.
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Tooling: Tooling section consists auger agitator, funnels and other filling components to finetune the machine depending on the type of material being filled.
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Structure Body: This is basic structure that supports the entire system.
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Controls: This is the main mechanism to operate the machine parameters.
Technical Specification of Powder Filler Machine
| Models | AI-APF 1 | AI-APF 2 | AI-APF 3 |
| Production Output | Up to 30 bottles/minute | Up to 60 bottles/minute | Up to 90 bottles/minute |
| Fill Volume | 5gms. to 60gms. in Single Dose System | 5gms. to 60gms. in Single Dose System | 5gms. to 60gms. in Single Dose System |
| Container Size | Custom made as per required container size | Custom made as per required container size | Custom made as per required container size |
| Filling Accuracy | ± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Powder | ± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Powder | ± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Powder |
| Power Load | 2 H. P. | 3 H. P. | 4.5 H. P. |
| Overall Dimension | 1810 mm (L) x 905 mm (W) x 1900 mm approx. | 2300 mm (L) x 905 mm (W) x 1900 mm approx. | 3000 mm (L) x 905 mm (W) x 1900 mm approx. |
| Conveyor Height | 850 – 950 mm adjustable | 850 – 950 mm adjustable | 850 – 950 mm adjustable |
| Electrical | 415VAC 3Phase and 220 VAC Single Phase Power Supply (50 Hz) with A.C. Drive | 415VAC 3Phase and 220 VAC Single Phase Power Supply (50 Hz) with A.C. Drive | 415VAC 3Phase and 220 VAC Single Phase Power Supply (50 Hz) with A.C. Drive |
* 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.
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