Parenterals Vial Powder Filling Machine

Parenterals Vial Powder Filling Machine are specialized pharmaceutical equipment designed for the aseptic filling of sterile dry powders into glass or plastic vials used for injectable drugs. These machines ensure precise dosing, minimize contamination risks, and comply with cGMP standards, including operations in cleanroom environments. They typically integrate filling, stoppering (bunging), and sometimes capping in a monoblock setup to maintain sterility and efficiency.

Vial Powder Filling Machine are essential for small-volume parenterals (SVPs), handling vials from 2 ml to 50 ml, and are used in high-value biopharma production where accuracy is critical to avoid product loss.

Parenterals Vial Powder Filling Machine Video

Key Features and Technologies

Common features across models include:

• Filling Mechanism: Vacuum or servo-driven powder wheels for volumetric dosing, achieving accuracy of ±2%. Agitators in the powder hopper maintain uniform bulk density.

• Stoppering System: Built-in rubber stopper insertion under laminar airflow for sterility.

• In-Process Control (IPC): 100% weighing and rejection of under/over-filled vials to prevent waste.

• Safety and Flexibility: Clutch systems for vial breakage protection, tool-less adjustments, multiple dosing via change parts, and optional PLC interfaces with GUI for automation.

• Containment: Modular designs for RABS or isolators, with inbuilt laminar airflow for Class 100 filling zones.

How They Work

1. Infeed: Sterilized vials are fed via turntables or star wheels into the machine at controlled speeds.

2. Powder Dosing: Powder from a hopper is drawn into dosing wheels (vacuum-assisted) and dispensed into vials. Servo motors adjust for precision.

3. Weighing/IPC: Each vial is weighed in real-time; non-conforming units are rejected.

4. Stoppering: Rubber stoppers are partially inserted (bunged) under sterile conditions.

5. Outfeed: Vials exit for capping, labeling, or further processing (e.g., lyophilization).

6. Cleaning: Contact parts (SS316) are autoclavable; the system supports CIP/SIP cycles.

This process operates at speeds from 60–450 vials per minute (VPM), with higher outputs for medium-to-large batches.

Working Principle of Vial Powder Filler

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 Vial 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.