Vial Powder Filling and Stoppering Machine

Q: How does the Vial Powder Filling and Stoppering Machine ensure filling accuracy and sterility?

Filling accuracy is typically ±2% to ±3% depending on the consistency and uniformity of the powder’s bulk density. Sterility is maintained through: “ No Vial – No Filling ” system to prevent powder wastage and contamination. Built-in rubber stoppering unit that immediately seals vials, reducing laminar airflow length and exposure to the environment. All product contact parts are easily removable for autoclaving/sterilization. Operation under Laminar Air Flow (Class 100) with optional nitrogen flushing. Safety clutch to avoid vial breakage. The machine meets strict USFDA, cGMP, and WHO guidelines for injectable powder filling.

Q: What are the power requirements and key features of the Vial Powder Filling and Stoppering Machine?

Power requirements are model-specific: APF 12S : 3.5 HP APF 12D : 4.5 HP (Power voltage is customizable as per your country’s requirements, typically 440 Volts, 3 Phase, 50 Hz.) Key features include: Variable AC frequency drive for speed control Digital production counter Agitated powder hopper with mechanical agitators for uniform bulk density Individual drives for filling and stoppering Safety clutch and overload protection Easy integration with vial washing, depyrogenation, capping, and labeling machines for a complete production line.

Description

Vial Powder Filling and Stoppering Machine (also called Auger Powder Filler with stoppering unit or powder vial monobloc) is a specialized pharmaceutical packaging machine designed to automatically fill sterile powder (typically antibiotic, lyophilized, or injectable drugs) into glass or plastic vials and then insert rubber stoppers (full or lyophilization-type) under aseptic conditions.

This advanced cGMP-compliant machine is ideal for pharmaceutical and biotech manufacturers producing antibiotics, vaccines, lyophilized drugs, and other sterile powder injectables. It ensures precise dosing, minimal contamination risk, and maximum production efficiency while meeting stringent USFDA, WHO, and cGMP guidelines.

Sterilized powder is stored in a hopper with mechanical agitators to maintain uniform bulk density. The powder wheel (with eight ports and pistons) rotates below the hopper. Vacuum suction draws precise powder volumes into the ports based on piston depth. Excess powder is removed by an adjustable doctor blade. Compressed air or nitrogen then flushes the powder into the vial. Filled vials move via conveyor to the built-in stoppering unit, where siliconized rubber stoppers are automatically picked from a vibratory bowl and pressed firmly into place using timing belts and pressing rollers.

Salient Features of Vial Powder Filling and Stoppering Machine

Compact cGMP model.
“No Vial, No Filling” system eliminates wastage of costly powder.
Variable AC Frequency Drive for speed adjustment.
Multiple Dosing System.
Safety clutch system to avoid Vial breakage.
Digital counter for counting production output.

Built-in Rubber Stoppering Unit saves lot of space in the Sterile Area & reduces the length of Laminar Flow.
Individual drive for the filling & sealing to match the speed of filling & sealing.
All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.
High Volumetric Filling Accuracy of ±2% of uniform density Injectable powder can be ensured by setting the depth of piston in the port of powder wheel.
All contact parts are easily removable for mandatory Autoclaving/ Sterilization.

Working Principle of Vial Powder Filling and Stoppering 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 Filling and Stoppering 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

Advantages of Vial Powder Filling and Stoppering Machine

High Filling Accuracy and Repeatable Precision

Integrated Rubber Stoppering for Superior Sterility

High Production Speed and Efficiency

Minimal Product Wastage and Lower Operating Costs

Easy Changeover, Flexibility, and Regulatory Compliance

Key Components of Vial Powder Filling and Stoppering Machine

Vial feeding & transport – Vibratory bowl or centrifugal unscrambler + infeed conveyor/starwheel

Tare weighing (optional, for 100% IPC – In-Process Control)

Powder dosing – Servo-driven auger filler (most common) or vacuum-pressure filling for very low-density powders

Gross weighing (optional, for check-weighing and feedback loop to auger)

Stopper insertion – Pick-and-place or vibratory bowl + vacuum starwheel; half or full stoppering

Reject station for under/over-filled or unstoppered vials

Outfeed to crimping/capping machine or tray loader

FAQ for Vial Powder Filling and Stoppering Machine

What is a Vial Powder Filling and Stoppering Machine and what does it do?

The Vial Powder Filling and Stoppering Machine is a compact, fully automatic monoblock system designed to fill sterilized glass vials with injectable dry powders (such as antibiotics, vaccines, or lyophilized drugs) and immediately apply rubber stoppers in one continuous operation. It uses a vacuum-pressure powder wheel with an agitated hopper for precise volumetric dosing, followed by a built-in stoppering unit with vibratory bowl, chute, and pressing rollers. This ensures high sterility, minimal contamination, and compliance with cGMP standards for pharmaceutical and biotech production.

What is the production capacity of the Vial Powder Filling and Stoppering Machine?

Our Vial Powder Filling and Stoppering Machine is available in two models:

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

The actual output depends on vial size, powder characteristics, fill weight, and bulk density. It supports high-speed sterile production while maintaining consistent performance.

Which vial sizes and fill volumes can the Vial Powder Filling and Stoppering Machine handle?

The machine handles a wide range of vial sizes from 5ml to 250ml. It can accurately fill powder doses from 50 mg to 10 grams per vial (in single or multiple dosing). Changeover between different vial sizes is quick with minimum change parts. The versatile design makes it suitable for both small-batch and large-scale sterile powder filling in pharmaceutical production.

How does the Vial Powder Filling and Stoppering Machine ensure filling accuracy and sterility?

Filling accuracy is typically ±2% to ±3% depending on the consistency and uniformity of the powder’s bulk density. Sterility is maintained through:

“No Vial – No Filling” system to prevent powder wastage and contamination.
Built-in rubber stoppering unit that immediately seals vials, reducing laminar airflow length and exposure to the environment.
All product contact parts are easily removable for autoclaving/sterilization.
Operation under Laminar Air Flow (Class 100) with optional nitrogen flushing.
Safety clutch to avoid vial breakage.

The machine meets strict USFDA, cGMP, and WHO guidelines for injectable powder filling.

What are the power requirements and key features of the Vial Powder Filling and Stoppering Machine?

Power requirements are model-specific:

APF 12S: 3.5 HP
APF 12D: 4.5 HP

(Power voltage is customizable as per your country’s requirements, typically 440 Volts, 3 Phase, 50 Hz.)

Key features include:

Variable AC frequency drive for speed control
Digital production counter
Agitated powder hopper with mechanical agitators for uniform bulk density
Individual drives for filling and stoppering
Safety clutch and overload protection
Easy integration with vial washing, depyrogenation, capping, and labeling machines for a complete production line.

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