Automatic Vial Powder Filling Machine

Q: What are the key features of the Automatic Vial Powder Filling Machine?

cGMP-Compliant Construction : SS 316L product contact parts and SS 304 non-contact parts. High Accuracy : ±1% to ±3% filling precision with vacuum-pressure or auger-based dosing systems. High Speed : Output up to 100–450 vials per minute depending on the model and number of heads. Safety Systems : “No Vial – No Filling” mechanism and safety interlocks. Advanced Controls : PLC + HMI interface, variable frequency drive, and easy integration with laminar airflow or isolators. Quick Changeover : Tool-less adjustments for different vial sizes (typically 5ml to 250ml).

Q: What are the main advantages of an Automatic Vial Powder Filling Machine?

Precision and Low Waste : Consistent dosing reduces product loss and ensures dosage accuracy. Sterility Assurance : Designed for aseptic operation with minimal human intervention. High Efficiency : Supports large-scale production with fast changeovers and low maintenance. Regulatory Compliance : Easy validation (IQ/OQ) and meets USFDA, WHO, and cGMP requirements. Versatility : Handles a wide range of powder types and vial sizes while integrating seamlessly into complete filling lines.

Description

Automatic Vial Powder Filling Machine are specialized pharmaceutical equipment designed to precisely fill sterile powders into glass vials under aseptic conditions. These machines ensure compliance with cGMP standards, minimize contamination risks, and integrate processes like filling, stoppering, and capping. They are essential in the production of injectable powders, handling vial sizes from 2R to 100 ml, with speeds ranging from 100 to 450 vials per minute depending on the model. They ensure accurate dosage, minimize contamination risks, and comply with cGMP, USFDA, WHO, and other international regulatory standards. Models range from standard automatic to high-speed variants, making them suitable for both small-batch and large-scale production.

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Salient Features of Automatic Vial Powder Filling Machine

Compact cGMP model.
“No Vial, No Filling” system eliminates wastage of costly powder.
High Volumetric Filling Accuracy of ±2% of uniform density Injectable powder can be ensured by setting the depth of piston in the port of powder wheel.
All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.
Individual drive for the filling & sealing to match the speed of filling & sealing.

Built-in Rubber Stoppering Unit saves lot of space in the Sterile Area & reduces the length of Laminar Flow.
Multiple Dosing System.
Safety clutch system to avoid Vial breakage.
Variable AC Frequency Drive for speed adjustment.
All contact parts are easily removable for mandatory Autoclaving/ Sterilization.
Digital counter for counting production output.

Working Principle of Automatic Vial Powder Filling Machine

The sterilized powder is stored in powder hopper is agitated by pair of mechanical agitators for maintaining consistency and uniform bulk density. The powder wheel having eight ports rotates at the predetermined speed below the powder hopper with practically no clearance. Powder wheel consist of Piston in each port and behind the powder wheel vacuum plate is provided there is no clearance between powder wheel and vacuum plate due to back spring pressure. Precise volume of powder is sucked in to the port of powder wheel during vacuum according to the piston length different fill size can be achieved. The excess powder is doctored off by a doctor blade. Doctor blades can be adjusted from outside also without removing powder hopper. When powder wheel indexes further and remain in the port due to the vacuum till it reaches just vertically above the container. The time dose of Compressed air (Nitrogen Gas), sterilized low pressure air sequentially flushes out powder from the port of powder wheel in to the container one by one. The filled containers are immediately separated on the conveyor by vial separator and moves further for stoppering operation. (Different grooves separator can be used which depends on the container diameter or multiple dosing systems). The sterilized, siliconized, rubber stoppers stored in the vibrator bowl moves to vibratory bowl and stacked vertically in the rubber stopper chute. The container is hold firmly between pair or timing belt to pick up rubber stopper from exit end of the chute. Further the container is passed between two pressing roller for tight fit fixing of rubber stopper.

Technical Specification of Automatic Vial Powder Filling Machine

Models	APF 12S	APF 12D
Production Output	Up to 100 vials/minute	Up to 200 vials/minute
Fill Volume	50 mg. to 10grams	50 mg. to 10 grams
Vial Size	5ml to 250ml	5ml to 250ml
Filling Accuracy	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder
Power Load	3.5 H. P.	4.5 H. P.
Overall Dimension	2600mm (L) X 1100mm (W) X 1800mm (H) approx.	3000mm (L) X 1100mm (W) X 1800mm (H) approx.
Net Weight	500 kgs. approx.	700 kgs. approx.
Gross Weight	750 kgs. approx.	950 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 Powder Filling Machines

Antibiotic Powder Filling Machine

Injectable Powder Filling Machine

Auger Powder Filling Machine

Bottle Dry Injectable Filling Machine

Automatic Dry Syrup Powder Filling Machine

Dry Syrup Powder Filler Capper

Dry Syrup Powder Filling Machine

Double Head Auger Powder Filling Machine

Applications of Powder Filling Machines

Advantages of Automatic Vial Powder Filling Machine

High production output with low product wastage.

Excellent sterility and product stability.

Easy integration into complete vial washing → filling → capping lines.

Low maintenance, quick cleaning, and minimal changeover time.

Key Features of Automatic Vial Powder Filling Machine

Filling Mechanism: Typically uses volumetric methods like vacuum/pressure systems or auger screws for accurate dosing. Some advanced models employ 100% in-process control (IPC) weighing to avoid product loss.

Aseptic Design: Stainless steel construction, laminar airflow integration, and compatibility with isolators or RABS for sterile environments.

Additional Functions: Inline stoppering, capping, and optional washing/depyrogenation integration.

Customization: Options for single/double tracks, multiple powder wheels, or hybrid liquid/powder setups.

FAQ for Automatic Vial Powder Filling Machine

What is an Automatic Vial Powder Filling Machine?

An Automatic Vial Powder Filling Machine is a specialized pharmaceutical equipment designed to accurately dose and fill sterile dry powders into glass or plastic vials under aseptic conditions. It typically integrates powder dosing, filling, and rubber stoppering (often in monoblock design) for the production of injectable powder formulations such as antibiotics, vaccines, and lyophilized products. These machines ensure high precision, minimal contamination, and compliance with cGMP standards.

What are the key features of the Automatic Vial Powder Filling Machine?

cGMP-Compliant Construction: SS 316L product contact parts and SS 304 non-contact parts.
High Accuracy: ±1% to ±3% filling precision with vacuum-pressure or auger-based dosing systems.
High Speed: Output up to 100–450 vials per minute depending on the model and number of heads.
Safety Systems: “No Vial – No Filling” mechanism and safety interlocks.
Advanced Controls: PLC + HMI interface, variable frequency drive, and easy integration with laminar airflow or isolators.
Quick Changeover: Tool-less adjustments for different vial sizes (typically 5ml to 250ml).

How does the Automatic Vial Powder Filling Machine work?

Sterilized vials are fed via an in-feed turntable or unscrambler onto the conveyor. The machine uses a powder dosing system (such as a powder wheel or auger) to precisely fill the powder into the vials. Agitated hoppers and doctor blades ensure uniform powder density. Filled vials then move to the stoppering station for automatic placement of rubber stoppers under controlled aseptic conditions. Sensors monitor the process, and optional nitrogen flushing helps maintain product stability.

What are the main advantages of an Automatic Vial Powder Filling Machine?

Precision and Low Waste: Consistent dosing reduces product loss and ensures dosage accuracy.
Sterility Assurance: Designed for aseptic operation with minimal human intervention.
High Efficiency: Supports large-scale production with fast changeovers and low maintenance.
Regulatory Compliance: Easy validation (IQ/OQ) and meets USFDA, WHO, and cGMP requirements.
Versatility: Handles a wide range of powder types and vial sizes while integrating seamlessly into complete filling lines.

Which industries and products is the Automatic Vial Powder Filling Machine suitable for?

It is primarily used in the Pharmaceutical, Biotech, Nutraceutical, and Veterinary industries. The machine is ideal for sterile injectable powders, antibiotics, vaccines, lyophilized drugs, and other dry powder formulations in vials ranging from small to medium sizes.

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