R&D Ampoule Filler

An R&D Ampoule Filler also known as a lab-scale or pilot ampoule filling and sealing machine is a compact, specialized piece of pharmaceutical equipment designed for research and development (R&D) or small-batch production. It automates the process of filling glass ampoules with liquids (such as injectables, cosmetics, agro-chemicals, or veterinary medicines) and sealing them hermetically to maintain sterility and prevent contamination. These machines are ideal for laboratories, pilot plants, or low-volume manufacturing where flexibility and precision are key, typically handling 1ml to 25ml ampoules at speeds of 10–50 units per minute.

Unlike high-speed production fillers (which can process 300+ ampoules/min), R&D models prioritize ease of setup, minimal maintenance, and compliance with standards like cGMP (current Good Manufacturing Practices) and US FDA requirements. They often feature stainless steel 316L construction for corrosion resistance and autoclavable contact parts for sterilization.

R&D Ampoule Filler Video

How It Works

1. Loading: Empty ampoules (1–20ml) are loaded into a hopper and fed onto a traveling rack via starwheel (single to eight-head formats).

2. Purging: Ampoules move to nitrogen stations for pre- and post-filling gas flush to displace air.

3. Filling: Needles dispense precise liquid volumes; neck centering avoids spills.

4. Pre-Heating & Sealing: Ampoules rotate under burners to melt the glass neck, then a clipper trims excess for a smooth seal.

5. Ejection: Filled/sealed ampoules are diverted to a collection tray.

This process ensures a fully automated, sterile workflow suitable for R&D trials.

Applications

• Pharmaceuticals: Filling injectable drugs, antibiotics, or sterile liquids.

• Cosmetics & Veterinary: Packaging serums, oils, or animal meds.

• Chemicals/Agro: Small batches of insecticides or reagents.

• Lab/Pilot Scale: Testing formulations before scaling to production lines (e.g., integrated with washers, tunnels, or labelers).

Salient Features of Small Ampoule Filling Machine R&D Model

• Small footprint equipment.

• 1ml-30ml ampoule size suitability.

• Monobloc design with filling and sealing units combined.

• Different filling mechanism models available.

• Acceptable error range of ± 1%.

• Safety guards with guide railing on demand.

• Class 100 Laminar Air Flow can be installed optionally.

• Contact Area parts suitable for Autoclaving / Sterilization.

• Frequency drive unit for speed variation.

• IQ/OQ validation protocols on demand.

• PLC system with Graphical User Interface in special models.

Process Operation of Small Ampoule Filling Machine

Machine having hopper for storing ampoules. User has to load empty ampoules on this hopper in bulk from where ampoule deliver onto moving rack one by one. In the movement over rack ampoule reaches to the filling station where filling needles fill preset volume of liquid in ampoules. Further ampoules reached to the sealing station where two burner nozzles installed in which first one is preheating nozzle and second is sealing nozzle. Rollers provided for rotation of ampoules, so evenly heating provided on all around the ampoule neck. During rotation of ampoule with nozzle gassing, the glass of ampoule get melt. Sealing clipper installed which do up & down movement above sealing unit. During down movement clipper take off excess melt part of ampoules and drop into waste glass collection box. Duly filled and packed ampoules get collected onto delivery tray of the machine.

Technical Specification of Ampoule 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.