Dry Injection Preparation Machine

A Dry Injection Preparation Machine, commonly referred to as an Injectable Dry Powder Filling Machine or Vial Powder Filler, is specialized pharmaceutical equipment used to fill sterile dry powders into glass vials or ampoules for injectable medications. These machines ensure precise dosing, sterility, and compliance with cGMP standards, making them essential for producing powder-based injectables that are reconstituted with liquid before administration. They are distinct from liquid filling machines and are widely used for drugs unstable in aqueous solutions, like beta-lactam antibiotics or acyclovir.

Unlike water restoration tools, these machines focus on pharmaceutical preparation, handling everything from powder dosing to stoppering in a controlled, aseptic environment.

Dry Injection Preparation Machine Video

Key Features and Components

Dry Injection Preparation Machine typically operate as monobloc systems for efficiency. Common features include:

• Powder Wheel: Vacuum-driven or auger-based for accurate filling.

• Conveyor System: Stainless steel slat belts for hygienic vial transport.

• Stoppering Unit: Automatic placement of rubber bungs.

• Controls: PLC with HMI touchscreens and servo motors for variable speed and precision.

• Turntables: For smooth infeed/outfeed of vials.

• Integration: Often part of a full line with washing, sterilizing tunnels, capping, and labeling machines.

They support outputs from 60 to 240 vials per minute (VPM), depending on vial size, powder type, and configuration.

How It Works

1. Vial Feeding: Empty sterile vials are loaded via turntables or hoppers onto the conveyor.

2. Orientation and Transport: Vials are aligned and moved through the machine using slat belts.

3. Powder Filling: A rotating powder wheel or auger dispenses exact powder amounts into each vial under vacuum for minimal dust and high accuracy.

4. Stoppering: Rubber stoppers are inserted partially or fully to seal the vial while allowing needle insertion.

5. Capping/Sealing: Optional aluminum seals or caps are crimped on.

6. Outfeed and Inspection: Filled vials exit for labeling, packaging, or quality checks.

7. Cleaning/Sterilization: Integrated or upstream systems use WFI rinses and hot air tunnels for aseptic preparation.

Advanced models incorporate servo technology for consistency and can handle innovative forms like spray-freeze-dried pellets.

Applications

• Pharmaceuticals: Filling sterile powders for injectables.

• Biotech: Lyophilized proteins or vaccines.

• Other Industries: Adapted for cosmetics, food powders, or chemicals requiring precise dry dosing.

Salient Features of Dry Injection Preparation 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 Dry Injection Preparation 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 Dry Injection Preparation 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.