Biotech Powder Filling Machine for Vials

The Biotech Powder Filling Machine for Vials is a high-precision, automated system designed for filling fine powders into small-volume vials used in biotechnology and pharmaceutical applications. Engineered for sterile and aseptic environments, it handles sensitive biological powders such as lyophilized biologics, vaccines, APIs, and cell/gene therapy compounds. The machine ensures accurate dosing, minimal contamination, and compliance with stringent regulatory standards. It supports small-scale R&D, clinical trials, and high-speed commercial production, with output rates ranging from 30 to 400 vials per minute depending on configuration.

Biotech Powder Filling Machine Video

Key Features

• High-Accuracy Dosing: Employs servo-driven auger fillers, gravimetric weigh cells, or vacuum-pressure dosing for precise filling. Ideal for high-potency or low-dose biotech powders.

• Aseptic Processing: Integrates isolators, RABS, or laminar flow hoods with HEPA filtration for ISO Class 5 cleanroom compatibility. Supports Sterilization-in-Place (SIP) and Cleaning-in-Place (CIP) for contamination-free operation.

• Vial Compatibility: Handles glass or plastic vials, with quick-change tooling for different sizes/formats, including pre-sterilized or ready-to-use (RTU) vials.

• In-Process Control (IPC): Real-time weight verification with automatic rejection of non-compliant vials, ensuring 100% quality control and minimal product loss.

• Flexible Integration: Operates standalone or in-line with vial washing, depyrogenation, stoppering, and capping systems. Modular design allows seamless scalability.

• Advanced Controls: Touchscreen HMI with recipe storage for rapid changeovers. Includes dust extraction, vibration, or stirring mechanisms to manage cohesive or poorly flowing powders.

• Regulatory Compliance: Fully compliant with cGMP, FDA, and EU standards, offering data logging and audit trails for traceability.

Applications in Biotech

• Biologics and Vaccines: Fills lyophilized monoclonal antibodies, vaccine powders, or antibiotics with high precision for clinical and commercial use.

• Gene and Cell Therapies: Supports micro-dosing for costly or small-batch formulations, critical for personalized medicine.

• R&D and Clinical Trials: Enables small-scale filling for early-phase studies, ensuring flexibility for formulation adjustments.

• High-Potency Drugs: Safely handles potent APIs with containment systems to protect operators and maintain product integrity.

Salient Features of Biotech Powder Filler Machine

• Compact GMP Model.

• Suitable to fill 50mg to 1500mg in single dosing.

• Powder wheel rotation and vial transportation through servo motors.

• Vacuum driven specially designed Powder Wheels.

• All contact parts made of SS316L materials with easy removal system for Autoclaving / Sterilization.

• Filling Accuracy of ± 2% depending upon powder characteristics and environmental conditions.

• Built in Rubber Stoppering System.

• Multiple dosing system with the help of change parts.

• Built in Turn Tables with Separate Drive for speed control of infeed and outfeed of vials.

• Various safety features including Clutch system for Vial Breakage.

• Tool Less adjustment of Doctor Blade and Wiper Blade saves valuable time and easy for setting.

• IQ/OQ Validation documentation can be provided.

• PLC system with Graphical User Interface can be offered.

• Inbuilt Laminar Air Flow can be offered for sterile class 100 filling.

• Sampling and Rejection system can be provided on demand.

Process Operation of Powder Filler 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 twelve ports which rotates at pre-determined 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 into 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.

The sterilized, siliconised, 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 pickup rubber stopper from exit end of the chute. Further container is passed between two pressing roller for tight fit fixing of rubber stoppers.

Technical Specification of Powder Filling Machine

* 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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