Pharmaceutical Dry Powder Filling Machine

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

The machine provides a filling accuracy of ±2–3% depending on powder characteristics, bulk density uniformity, and environmental conditions. APF 12S (Single Head) : Up to 100 vials per minute APF 12D (Double Head) : Up to 200 vials per minute Fill range: 50 mg to 10 grams (up to 1500 mg in single dosing with change parts). It includes a “No Vial, No Fill” system to prevent powder wastage.

Description

Pharmaceutical Dry Powder Filling Machine are specialized equipment used in the pharmaceutical industry to accurately and sterilely fill dry powders—such as antibiotics, acyclovir, or lyophilized pellets—into vials, syringes, bottles, or sachets. These machines are essential for producing injectable or oral powder formulations that require stability and cannot be stored in liquid form. They ensure precise dosing, minimize dust and waste, and comply with strict cGMP (Current Good Manufacturing Practice) standards for sterility and contamination prevention.

Material Loading: Powder is loaded into a hopper, where agitation prevents clumping.

Filling: An auger screw or vacuum wheel meters and dispenses the exact powder volume into containers via funnels. Servo-driven systems ensure consistent dosing.

Stoppering/Bunging: Rubber stoppers are inserted partially or fully, often for lyophilization compatibility.

Capping/Sealing: Aluminum seals or screw caps are applied to prevent contamination and ensure tamper-proof packaging.

Inspection and Ejection: Automated checks for fill levels, then filled containers are ejected for downstream processes like labeling.

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Salient Features of Pharmaceutical Dry Powder Filling 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 Pharmaceutical Dry 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 Pharmaceutical Dry Powder Filling 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 Pharmaceutical Dry Powder Filling Machine

Superior Sterility and Product Safety

High Filling Accuracy and Minimal Wastage

Increased Efficiency and High-Speed Production

Hygienic Design, Easy Maintenance & Versatility

Regulatory Compliance and Quality Assurance

Key Features of Pharmaceutical Dry Powder Filling Machine

Precision and Accuracy: Utilizes auger, volumetric, or vacuum-driven mechanisms to achieve filling accuracy within ±1-2%, critical for dosage-sensitive drugs.

Sterility: Operates in cleanroom environments with isolator or RABS technology to separate operators from the product.

Versatility: Handles free-flowing and non-free-flowing powders, granules, or pastes; supports various container sizes and optional stoppering, capping, or sealing.

Efficiency: High-speed models fill 80-240 vials per minute, reducing manual labor and production time while minimizing powder loss.

Customization: Modular designs allow integration of weighing modules, servo motors for vibration-free operation, and PLC/HMI controls for easy setup and validation.

FAQ for Pharmaceutical Dry Powder Filling Machine

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

A Pharmaceutical Dry Powder Filling Machine is a cGMP-compliant aseptic system designed to accurately fill sterile dry powders (such as antibiotics, acyclovir, or lyophilized pellets) into vials under controlled sterile conditions. It uses a vacuum-driven powder wheel with pistons: sterilized powder is agitated in the hopper for uniform bulk density, sucked into the wheel ports via vacuum, excess powder is removed by a doctor blade, and then flushed into vials using compressed or nitrogen gas. Filled vials are immediately stoppered to maintain sterility.

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

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

APF 12S (Single Head): Up to 100 vials per minute
APF 12D (Double Head): Up to 200 vials per minute Fill range: 50 mg to 10 grams (up to 1500 mg in single dosing with change parts). It includes a “No Vial, No Fill” system to prevent powder wastage.

What types of products and vial sizes can it handle?

It is ideal for sterile dry powder injectables and oral formulations in the pharmaceutical and biotech industries, including antibiotics and other sensitive APIs. The machine handles vial sizes from 5 ml to 250 ml and supports various powder types with consistent flow properties. It is designed for operation in Class 100 / ISO 5 cleanroom environments.

What are the key features of the Pharmaceutical Dry Powder Filling Machine?

Compact cGMP model with SS316L contact parts (easily removable for autoclaving).
Servo-driven powder wheel and vial transport, built-in turn tables, and safety clutch for vial breakage protection.
Tool-less doctor & wiper blade adjustment, built-in rubber stoppering, and multiple dosing capability.
Vacuum-driven powder wheels, options for inbuilt Laminar Air Flow (Class 100), PLC/HMI, IQ/OQ documentation, and sampling/rejection systems.

What are the main advantages of using this machine?

Superior sterility assurance and product safety for injectable powders.
High precision dosing with minimal wastage.
High-speed automated production that reduces labor and increases efficiency.
Hygienic design for easy cleaning, fast changeover, and low maintenance.
Full regulatory compliance (cGMP, FDA) with easy validation and integration into complete sterile lines.

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