Injectable Filling Stoppering Machine

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

The machine is available in two models: APF 12S (Single Head) : Up to 100 vials per minute APF 12D (Double Head) : Up to 200 vials per minute Fill volume ranges from 50 mg to 10 grams (with multiple dosing options). Filling accuracy is ±2% to ±3% , depending on powder bulk density uniformity and environmental control.

Q: What are the key features of the Injectable Filling Stoppering Machine?

Compact cGMP model with built-in rubber stoppering unit “ No Vial – No Fill ” system to eliminate wastage Vacuum powder wheel with adjustable piston depth and multiple dosing Safety clutch for vial breakage protection and overload protection Individual drives for filling & stoppering with variable AC frequency drive Easy-to-remove SS316L contact parts for autoclaving and tool-less adjustments Digital production counter and optional PLC/HMI, Laminar Air Flow (Class 100), and IQ/OQ documentation These features ensure high sterility, efficiency, and ease of operation.

Description

Injectable Filling Stoppering Machine is a specialized piece of pharmaceutical packaging equipment designed for the aseptic filling of liquid or powder formulations into sterile vials (or sometimes syringes/cartridges) and the subsequent insertion of rubber stoppers (bungs) to seal them. These machines are essential in the production of injectable drugs, such as vaccines, antibiotics, and biologics, ensuring high precision, sterility, and compliance with standards like cGMP and FDA regulations. They minimize contamination risks by operating under laminar airflow and using stainless steel components for product contact surfaces.

Infeed: Empty, sterilized vials are fed via a turntable or conveyor belt.

Filling: Syringes, nozzles, or powder wheels dispense the exact volume while the vial moves. Nitrogen flushing may occur pre- and post-fill to displace oxygen.

Stoppering: A vibrating bowl feeds rubber stoppers into a chute; pneumatic or mechanical presses insert them partially or fully.

Outfeed: Stoppered vials exit for capping, labeling, or further processing.

Safety Features: Includes “no vial, no fill” sensors, machine stop on empty stopper chute, and variable speed controls.

Injectable Filling Stoppering Machine often include HMI panels for easy operation and can be customized with 1–12 filling heads for scalability.

If you need details on specific models and pricing, let me know!

Salient Features of Injectable Filling Stoppering Machine

Compact GMP Model.
“No Vial, No Filling” system eliminates wastage of costly powder.
All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.
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.
Built-in Rubber Stoppering Unit saves lot of space in the Sterile Area & reduces the length of Laminar Flow.

Individual drive for the filling & sealing to match the speed of filling & sealing.
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 Injectable Filling Stoppering 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 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 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, 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 the container is passed between two pressing roller for tight fit fixing of rubber stopper.

Technical Specification of Injectable Filling Stoppering 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 Injectable Filling Stoppering Machine

High throughput for medium batches

reduced waste, contamination control, and flexibility for R&D to production scales.

Compact tabletop models suit labs, while full automatics handle high-volume lines.

Key Features of Injectable Filling Stoppering Machine

Compact cGMP Model

Designed as a space-saving, GMP-compliant monobloc unit ideal for sterile areas. Minimizes the length of Laminar Air Flow requirements.

“No Vial – No Fill” System

Advanced sensor-based system prevents wastage of costly injectable powder or liquid by ensuring filling occurs only when a vial is present.

Built-in Rubber Stoppering Unit

Integrated stoppering saves valuable sterile area space. Features vibrating bowl for stopper feeding and precise pneumatic/mechanical insertion for partial or full stoppering.

High Volumetric Filling Accuracy

Achieves ±2% to ±3% accuracy (depending on powder/liquid consistency and bulk density). Vacuum powder wheel with adjustable piston depth or multi-head syringe system ensures uniform dosing.

Multiple Dosing System

Supports single and multiple dosing for flexible fill volumes (50mg to 10g for powders; wide range for liquids).

Safety Features

Safety clutch system to prevent vial breakage

Overload protection for motors with contractors and relays

Machine stop on empty stopper chute

Individual Drives & Variable Speed Control

Separate drives for filling and stoppering operations. Variable AC Frequency Drive allows precise speed adjustment up to 100–200 vials per minute (model dependent).

Easy Cleaning & Sterilization

All product contact parts are SS316L, easily removable for autoclaving/sterilization. Tool-less adjustments for doctor blade and wiper.

Advanced Controls

Digital production counter, PLC with HMI (optional), and options for Laminar Air Flow (Class 100), nitrogen flushing, and IQ/OQ documentation.

Robust Construction

Sturdy design with vibration-free operation, suitable for vial sizes from 5ml to 250ml. Seamless integration into complete vial lines (filling → stoppering → capping → labeling).

FAQ for Injectable Filling Stoppering Machine

What is an Injectable Filling Stoppering Machine and how does it work?

An Injectable Filling Stoppering Machine is a monobloc aseptic system that fills sterile dry powders (or liquids) into vials and immediately inserts rubber stoppers to maintain sterility. It uses a vacuum-driven powder wheel with pistons: powder is agitated in the hopper for uniform density, sucked into wheel ports via vacuum, excess doctored off, and flushed into vials using compressed/nitrogen gas. Filled vials are then stoppered via a built-in vibrating bowl and pressing rollers. This integrated design minimizes contamination risks in sterile areas.

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

The machine is available in two models:

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

Fill volume ranges from 50 mg to 10 grams (with multiple dosing options). Filling accuracy is ±2% to ±3%, depending on powder bulk density uniformity and environmental control.

What types of vials and products can it handle?

It is designed for sterile dry powder injectables (e.g., antibiotics, vaccines, and biologics) in the pharmaceutical and biotech industries. Compatible vial sizes range from 5ml to 250ml. The system excels with powders of varying flow properties and supports both powder and liquid filling with appropriate change parts. All product contact parts are SS316L for easy sterilization and cGMP compliance.

What are the key features of the Injectable Filling Stoppering Machine?

Compact cGMP model with built-in rubber stoppering unit
“No Vial – No Fill” system to eliminate wastage
Vacuum powder wheel with adjustable piston depth and multiple dosing
Safety clutch for vial breakage protection and overload protection
Individual drives for filling & stoppering with variable AC frequency drive
Easy-to-remove SS316L contact parts for autoclaving and tool-less adjustments
Digital production counter and optional PLC/HMI, Laminar Air Flow (Class 100), and IQ/OQ documentation

These features ensure high sterility, efficiency, and ease of operation.

What are the maintenance and compliance aspects of the machine?

The machine is fully cGMP-compliant and ideal for sterile pharmaceutical production. All contact parts are easily removable for mandatory autoclaving/sterilization. Maintenance is user-friendly with tool-less doctor blade adjustments and robust construction. Regular procedures include cleaning the powder wheel, hopper, agitators, and stoppering components while maintaining controlled cleanroom conditions (temperature & humidity) for optimal performance.

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