Dry Powder Filling Bunging Machine

Q: What is the filling accuracy and production capacity of the machine?

The machine offers a filling accuracy of ±2–3% (depending on powder characteristics, bulk density uniformity, and environmental conditions). Single Head (APF 12S) : Up to 100 vials/minute Double Head (APF 12D) : Up to 200 vials/minute It can fill 50 mg to 10 grams per dose (up to 1500 mg in single dosing with change parts) and handles vial sizes from 5 ml to 250 ml .

Q: What are the key features and advantages of this machine?

Key Features include: Compact cGMP model with SS316L contact parts (easily removable for autoclaving). Servo-driven powder wheel and vial transport for precision. Tool-less adjustment of doctor and wiper blades. Built-in rubber stoppering system with no-vial/no-stopper detection. Options for inbuilt Laminar Air Flow (Class 100), PLC/HMI, IQ/OQ documentation, and sampling/rejection systems. Advantages : Superior sterility, high accuracy with minimal waste, high-speed automated operation, easy cleaning/changeover, and regulatory compliance.

Description

Dry Powder Filling Bunging Machine also known as an Injectable Powder Filling and Stoppering Machine is specialized pharmaceutical equipment designed to automate the precise filling of sterile dry powders into glass vials or bottles, followed immediately by the insertion of rubber bungs (stoppers) to seal them. This monoblock (single-platform) system ensures sterility, accuracy, and efficiency in high-volume production, minimizing contamination risks in cleanroom environments. It’s a critical component in injectable drug manufacturing lines, often integrated with vial washing, sterilization, capping, and labeling stations. Dry Powder Filling Bunging Machine are cGMP-compliant (Current Good Manufacturing Practice) and commonly use servo motors, PLC controls, and vacuum-driven powder wheels for operation.

Vial Feeding: Empty sterile vials enter via turntables or slat conveyor belts.

Powder Preparation: Sterile powder is loaded into a hopper with mechanical agitators to maintain uniform bulk density.

Filling: Vials are positioned under a vacuum-driven powder wheel. Pistons in the wheel ports dispense exact powder amounts.

Bunging/Stoppering: Rubber stoppers (dry or wet) are automatically placed and pressed into vials—half for freeze-drying processes or full for immediate sealing.

Output: Filled and bunged vials exit to downstream equipment like cap sealers; rejects are sampled if needed.

Cleaning: Contact parts are removable for sterilization between batches.

The process is fully automated, with speeds up to 240 vials per minute (VPM), depending on vial size, powder type, and fill volume.

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Salient Features of Dry Powder Filling Bunging Machine

Compact GMP Model.
Built in Turn Tables with Separate Drive for speed control of infeed and outfeed of vials.
Powder wheel rotation and vial transportation through servo motors.
Various safety features including Clutch system for Vial Breakage.
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.
Tool Less adjustment of Doctor Blade and Wiper Blade saves valuable time and easy for setting.

Built in Rubber Stoppering System,Multiple dosing system with the help of change parts.
Suitable to fill 50mg to 1500mg in single dosing.
Vacuum driven specially designed Powder Wheels.
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.

Working Principle of Dry Powder Filling Bunging 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 Powder Filling Bunging 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 Machine

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 Machine

Advantages of Dry Powder Filling Bunging Machine

High Production Throughput and Efficiency

Superior Filling Accuracy and Minimal Waste

Enhanced Sterility and Product Safety

Space Saving and Compact GMP Design

Regulatory Compliance and Cost Efficiency

Key Features of Dry Powder Filling Bunging Machine

Compact Design: Requires minimal space; easy to operate with touch-screen HMI and PLC controls.

No-Vial/No-Stopper Detection: Automatically halts if vials or rubber stoppers are missing, preventing errors and waste.

Filling Accuracy: ±1-2% volumetric precision, adjustable for powder density.

Versatile Stoppering: Supports half-bunging or full-bunging.

Digital Counter: Tracks filled vials for production monitoring.

Separate Drives: Independent motors for filling and bunging allow simultaneous operations, boosting throughput.

Sterile Components: All contact parts are autoclavable; optional inbuilt laminar airflow for Class 100 sterility.

Servo-Driven: Powder wheel rotation and vial transport via servo motors for smooth, adjustable speeds.

FAQ for Dry Powder Filling Bunging Machine

What is a Dry Powder Filling Bunging Machine and how does it work?

A Dry Powder Filling Bunging Machine (also known as Injectable Powder Filling and Stoppering Machine) is a monoblock system designed for sterile filling of dry powders into glass vials, followed immediately by rubber bung (stopper) insertion.

Sterile powder is agitated in a hopper for uniform density, then dosed precisely using a vacuum-driven powder wheel with pistons. Excess powder is removed by doctor blades, and the dose is flushed into vials with compressed/nitrogen air. Filled vials are then automatically stoppered (half or full bunging) to maintain sterility. The process ensures high accuracy and minimal contamination risk in cleanroom environments.

What is the filling accuracy and production capacity of the machine?

The machine offers a filling accuracy of ±2–3% (depending on powder characteristics, bulk density uniformity, and environmental conditions).

Single Head (APF 12S): Up to 100 vials/minute
Double Head (APF 12D): Up to 200 vials/minute

It can fill 50 mg to 10 grams per dose (up to 1500 mg in single dosing with change parts) and handles vial sizes from 5 ml to 250 ml.

What types of powders and vials can this machine handle?

It is ideal for sterile injectable dry powders used in the pharmaceutical and biotech industries (e.g., antibiotics and other reconstitution powders). The machine handles a wide range of vial sizes (5 ml to 250 ml) and supports both dry and wet rubber stoppers. It is particularly suited for sensitive, high-value formulations requiring strict sterility.

What are the key features and advantages of this machine?

Key Features include:

Compact cGMP model with SS316L contact parts (easily removable for autoclaving).
Servo-driven powder wheel and vial transport for precision.
Tool-less adjustment of doctor and wiper blades.
Built-in rubber stoppering system with no-vial/no-stopper detection.
Options for inbuilt Laminar Air Flow (Class 100), PLC/HMI, IQ/OQ documentation, and sampling/rejection systems.

Advantages: Superior sterility, high accuracy with minimal waste, high-speed automated operation, easy cleaning/changeover, and regulatory compliance.

How do I maintain the machine and ensure long-term performance?

Contact parts are designed for easy removal and sterilization. Regular maintenance includes cleaning the powder hopper, powder wheel, doctor blades, and stoppering components. Use the built-in safety features (e.g., clutch system for vial breakage protection) and follow recommended cleaning protocols between batches. IQ/OQ validation documentation is available, and optional PLC systems help monitor performance. Proper humidity control (around 25%) and consistent powder bulk density ensure optimal results.

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Dry Powder Filling Bunging Machine

Description

Salient Features of Dry Powder Filling Bunging Machine

Working Principle of Dry Powder Filling Bunging Machine

Technical Specification of Dry Powder Filling Bunging Machine

Types of Powder Filling Machine

Applications of Powder Filling Machine

Advantages of Dry Powder Filling Bunging Machine

High Production Throughput and Efficiency

Superior Filling Accuracy and Minimal Waste

Enhanced Sterility and Product Safety

Space Saving and Compact GMP Design

Regulatory Compliance and Cost Efficiency

Key Features of Dry Powder Filling Bunging Machine

FAQ for Dry Powder Filling Bunging Machine

Countries We Export to

Partner with Industry Experts

Countries We Export to

Partner with Industry Experts

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