Injectable Powder Filling and Rubber Bunging Machine

An Injectable Powder Filling and Rubber Bunging Machine also known as a vial dry powder filling machine or sterile powder filler is a specialized piece of pharmaceutical equipment designed for the aseptic filling of dry powders into sterile glass vials, followed by the immediate application of rubber stoppers (bunging) to seal them. This monobloc system ensures minimal contamination risk, high precision, and compliance with cGMP standards, making it essential for parenteral drug manufacturing. These machines are widely used in the pharmaceutical industry to handle small, precise doses and support both full and half bunging for lyophilized products.

Injectable Powder Filling and Rubber Bunging Machine Video

Key Features and Functionality

Injectable Powder Filling and Rubber Bunging Machine typically operate in a sterile environment under laminar airflow or isolator systems, integrating filling and stoppering to reduce exposure time. Here’s a breakdown of core components and capabilities:

• Powder Wheel: Vacuum-driven rotary wheel with precision-machined ports and pistons for dosing powder via timed bursts of compressed air or nitrogen.

• Rubber Stoppering Unit: Vibratory bowl feeder stacks siliconized rubber bungs vertically; press-on mechanism for partial or full insertion.

• Conveyor and Turntable System: SS slat belt conveyor with infeed/outfeed turntables for smooth vial transfer.

• Safety and Compliance Features: SS 316L contact parts for autoclaving; air filters; PLC/touchscreen controls; optional RABS/isolator for 21 CFR compliance.

• Drive System: Servo-based or mechanical with AC variable frequency drives.

How It Works

1. Vial Feeding: Sterilized vials are loaded via turntable or unscrambler onto the SS conveyor.

2. Powder Filling: Vials enter the powder wheel station. Vacuum draws powder into ports, and sequential air/nitrogen pulses dispense exact doses into each vial. A separator ensures no carryover.

3. Bunging/Stoppering: Filled vials move to the stoppering chute. Rubber bungs are fed from a vibrator bowl and pressed into place.

4. Ejection and Inspection: Stoppered vials exit via conveyor for capping, labeling, or visual checks. Sensors halt operation if vials or stoppers are missing.

5. Cleaning/Validation: All contact parts are removable for SIP/CIP cycles.

Salient Features of Powder Filling and Rubber Bunging

• Compact cGMP model.

• “No Vial, No Filling” system eliminates wastage of costly powder.

• Multiple Dosing System.

• 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.

• All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.

• 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 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 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 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.