Vial Powder Feeding Machine

Q: What is a Vial Powder Feeding Machine?

A Vial Powder Feeding Machine (also referred to as Vial Powder Filling Machine) is a high-precision automatic system designed to accurately feed and dispense sterile dry powders into glass or plastic vials. It is widely used in the pharmaceutical, biotech, veterinary, and chemical industries for filling injectable powders such as antibiotics, vaccines, lyophilized drugs, and veterinary formulations. The machine integrates powder feeding from a hopper using a vacuum-driven powder wheel, followed by immediate rubber stoppering (bunging). It ensures dose uniformity, sterility, and minimal wastage while operating under Class 100 / ISO 5 laminar airflow and complying with cGMP, ISO, and FDA standards.

Q: What are the available models and production capacities of the Vial Powder Feeding Machine?

We offer two main models: APF 12S (Single Track) — Up to 100 vials per minute APF 12D (Double Track) — Up to 200 vials per minute The machine handles vial sizes from 5ml to 250ml and fill volumes from 50 mg to 10 grams (with multiple dosing option). Actual output depends on vial size, powder characteristics, and fill volume. It is suitable for both small-batch production and large-scale commercial manufacturing of sterile powders.

Q: What is the filling accuracy and key features for sterile operation?

The machine provides high filling accuracy of ±2% to ±3% , depending on powder consistency and bulk density. Key features for sterile operation include: All product contact parts made of AISI SS 316L , easily removable for autoclaving Built-in rubber stoppering system for immediate bunging after filling Optional inbuilt laminar airflow for Class 100 conditions PLC with Graphical User Interface, servo motors, and variable speed control Safety clutch system to prevent vial breakage Tool-less adjustments and “No Vial – No Filling” detection These ensure contamination-free operation and easy validation.

Description

Vial Powder Feeding Machine, more commonly known as a Vial Powder Filling Machine, is a specialized piece of pharmaceutical packaging equipment designed to accurately dispense sterile dry powders into glass vials. These machines are essential in the production of injectable medications, such as antibiotics, vaccines, or lyophilized (freeze-dried) drugs, where precise dosing and contamination prevention are critical. They ensure compliance with Good Manufacturing Practices (GMP) and standards like ISO and FDA regulations, minimizing human error and maintaining sterility. Unlike liquid fillers, powder fillers handle fine, dry substances that can be volatile or sensitive to moisture, using mechanisms like auger screws or vacuum dosing for uniform distribution.

Based on standard dry powder injection filling operations:

Vial Feeding: Empty, pre-washed, and sterilized vials are loaded via an automatic infeed turntable or conveyor. Orientation is ensured for proper alignment under filling nozzles.

Powder Preparation: Sterile powder is loaded into a hopper with mechanical agitators to maintain uniform bulk density and prevent clumping.

Dosing and Filling:
- An auger screw or vacuum/pressure wheel rotates to measure and dispense exact powder quantities into each vial.
- Servo-driven systems allow real-time adjustments for precision.

Stoppering: Rubber stoppers are automatically inserted (partial or full insertion) using a synchronized vibrator feed.

Capping/Sealing: Aluminum flip-off caps are crimped or sealed, often in-line.

Inspection and Outfeed: Vials pass through vision systems for fill-level checks, rejects defects, and exit via an outfeed turntable.

Cleaning: Tool-less disassembly for CIP (Clean-In-Place) or SIP (Sterilize-In-Place) to meet hygiene standards.

This process can be standalone or part of a full production line, including ultrasonic washing and hot-air sterilization.

If you need details on specific models, pricing, or comparisons with multi-head machines, let me know!

Salient Features of Vial Powder Feeding Machine

PLC system with Graphical User Interface can be offered.
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.

Multiple dosing system with the help of change parts.
Suitable to fill 50mg to 10 grams.
Vacuum driven specially designed Powder Wheels.
Built in Rubber Stoppering System.
IQ/OQ documentation can be provided.
Compact GMP Model.
Inbuilt Laminar Air Flow can be offered for sterile class 100 filling.
Sampling and Rejection system can be provided on demand.

Working Principle of Vial Powder Feeding 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 Vial Powder Feeding 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 Vial Filling Machine

Automatic Vial Filling Machine

High Speed Vial Filling Machine

Vial Liquid Filling Machine

Vial Powder Filling Machine

Automatic Vial Filling and Rubber Stoppering Machine

Lab Scale Vial Filling Stoppering & Cap Sealing Machine

Injectable Vial Powder Filling & Stoppering Machine

Peristaltic Pump based Vial Filling Machine

Applications of Vial Filling Machine

Benefits of Vial Powder Feeding Machine

Efficiency: Reduces waste and downtime with automated controls.

Scalability: From semi-automatic tabletops for labs to fully automated lines for mass production.

Key Components of Vial Powder Feeding Machine

Filling Accuracy: Typically ±1-2% deviation, depending on powder type and environmental factors.

Speed: Ranges from 40-600 vials per minute, scalable for small-batch or high-volume production.

Materials: Contact parts made of stainless steel (SS316L) for easy sterilization via autoclaving.

Safety: Includes vial breakage clutches, explosion-proof designs for volatile powders, and laminar airflow for Class 100 cleanrooms.

Automation: PLC controls with touchscreen interfaces, recipe storage for multiple products, and integration with washing, drying, stoppering, and capping lines.

Vial Compatibility: Handles 2ml-100ml vials, often with quick-change parts for different sizes.

FAQ for Vial Powder Feeding Machine

What is a Vial Powder Feeding Machine?

A Vial Powder Feeding Machine (also referred to as Vial Powder Filling Machine) is a high-precision automatic system designed to accurately feed and dispense sterile dry powders into glass or plastic vials. It is widely used in the pharmaceutical, biotech, veterinary, and chemical industries for filling injectable powders such as antibiotics, vaccines, lyophilized drugs, and veterinary formulations.

The machine integrates powder feeding from a hopper using a vacuum-driven powder wheel, followed by immediate rubber stoppering (bunging). It ensures dose uniformity, sterility, and minimal wastage while operating under Class 100 / ISO 5 laminar airflow and complying with cGMP, ISO, and FDA standards.

What are the available models and production capacities of the Vial Powder Feeding Machine?

We offer two main models:

APF 12S (Single Track) — Up to 100 vials per minute
APF 12D (Double Track) — Up to 200 vials per minute

The machine handles vial sizes from 5ml to 250ml and fill volumes from 50 mg to 10 grams (with multiple dosing option). Actual output depends on vial size, powder characteristics, and fill volume. It is suitable for both small-batch production and large-scale commercial manufacturing of sterile powders.

How does the powder feeding system work in the Vial Powder Feeding Machine?

The working principle involves a hopper with mechanical agitators that maintain uniform bulk density of the sterile powder and prevent clumping.

A vacuum-driven powder wheel with eight ports and pistons sucks a precise volume of powder. Excess powder is cleanly removed by a tool-less adjustable doctor blade. When the wheel positions over the vial, a timed pulse of compressed sterile air or nitrogen flushes the exact dose into the vial. The “No Vial – No Filling” system ensures powder is only dispensed when a vial is present, preventing wastage. Filled vials then move to the integrated stoppering unit.

What is the filling accuracy and key features for sterile operation?

The machine provides high filling accuracy of ±2% to ±3%, depending on powder consistency and bulk density.

Key features for sterile operation include:

All product contact parts made of AISI SS 316L, easily removable for autoclaving
Built-in rubber stoppering system for immediate bunging after filling
Optional inbuilt laminar airflow for Class 100 conditions
PLC with Graphical User Interface, servo motors, and variable speed control
Safety clutch system to prevent vial breakage
Tool-less adjustments and “No Vial – No Filling” detection

These ensure contamination-free operation and easy validation.

What are the main advantages of using a Vial Powder Feeding Machine?

The main advantages include:

Precise and consistent powder feeding with minimal wastage of expensive sterile powders
High production speed (up to 200 vials/min) with reduced labor costs
Enhanced sterility through compact monoblock design and immediate stoppering
Easy integration into complete injectable lines (washing → sterilization → filling → capping)
Compact cGMP-compliant structure with easy cleaning and format changeover
Safety features like overload protection and digital counters
Versatile for pharmaceutical, veterinary, and biotech applications (e.g., antibiotics and vaccines for animals)

It delivers higher yield, better dose uniformity, and strong ROI for manufacturers.

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