Injectable Powder Filling Machine

An Injectable Powder Filling Machine is a specialized piece of pharmaceutical equipment designed for the precise, sterile filling of dry powders into glass vials or bottles intended for injectable use. These machines ensure accurate dosing, typically ranging from 50 mg to 1,500 mg per vial, while maintaining aseptic conditions to meet cGMP (Current Good Manufacturing Practice) standards. They often integrate filling, rubber stoppering (bunging), and sometimes capping or labeling in a monobloc or linear setup, minimizing contamination risks and supporting high-speed production in cleanroom environments.

Injectable Powder Filling Machine are essential in the pharmaceutical, biotech, and nutraceutical industries for packaging cost-sensitive products like penicillin or cephalosporins, where precision is critical to avoid product loss and ensure patient safety.

Injectable Powder Filling Machine Video

Key Features and Components

• Filling Mechanism: Vacuum-driven or servo-based powder wheels with agitators to maintain uniform powder density and prevent bridging. Accuracy is typically ±2% depending on powder characteristics.

• Stoppering System: Integrated rubber stopper insertion for immediate sealing post-filling.

• Sterility Controls: Inbuilt laminar airflow, no-vial-no-fill sensors, low-air/vacuum stop systems, and optional 100% in-process control (IPC) weighing for quality assurance.

• Construction: Made from stainless steel for durability and easy cleaning/sterilization.

• Safety and Automation: HMI/PLC controls, vial counters, rejection systems, and sensors for powder levels or accumulation to prevent downtime.

How It Works

1. Vial Feeding: Empty sterilized vials are fed via a conveyor or rotary table.

2. Powder Agitation: Sterile powder in a hopper is agitated mechanically for consistency.

3. Filling: Vials are positioned under the powder wheel; vacuum and air pressure draw and dispense exact doses into each vial.

4. Stoppering: Rubber stoppers are automatically picked and pressed into the vials.

5. Output: Filled and sealed vials exit for downstream processes like capping, labeling, or inspection.

This process operates under controlled humidity and temperature to handle sensitive powders.

Applications

• Pharmaceuticals: Filling antibiotics, hormones, or API powders for reconstitution before injection.

• Biotech: Packaging lyophilized vaccines or biologics.

• Other: Adaptable for cosmetics or chemicals, though primarily sterile pharma-focused.

Salient Features of Injectable Powder Filler

• 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 Injectable Powder Filling 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 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.