Ampoule Filler

Q: What ampoule sizes and production capacities does your Ampoule Filler support?

Our Ampoule Filler machines handle ampoule sizes from 1 ml to 30 ml (model dependent; e.g., 1-20 ml for multi-head models). Available models include: Single Head (AFS-1) : Up to 25 ampoules/min Double Head (AFS-2) : Up to 50 ampoules/min Four Head (AFS-4) : Up to 100 ampoules/min Eight Head (AFS-8) : Up to 200 ampoules/min (maximum output up to 12,000 ampoules per hour). Filling precision is ±1%, with special capacity from 0.5 ml to 25 ml in a single dose.

Description

Glass ampoules are filled and sealed using the Ampoule Filler. The pharmaceutical, biotech, cosmetic, veterinary, and chemical industries all make extensive use of machines. We create Ampoule Filling and Sealing Machines using both our standard model and custom models based on the unique needs of our clients. The machine is designed to accommodate a wide range of ampoule neck dimensions, thicknesses, and ovality of available ampoules by using the principle of slant travel of ampoules during filling and sealing.

Ampoule filling machines, which include ampoule filling and sealing machines, are small devices with a monoblock configuration that allows for filling and sealing on a single platform. To prevent contamination, ampoules are sealed as soon as the liquid is filled. According to cGMP regulations, the machine is constructed from premium 316L stainless steel. All of the main unit drives are synchronised with a single motor, and a speed port is available for modifying speed. possesses both the pre and post-nitrogen flushing units and a nitrogen-flushing mechanism. The equipment’s ability to change ampoules as seldom as possible is one of its main advantages. In addition, an active pre-heating unit for thick glass ampoules is a feature of glass tube filler equipment. The machine can fill seal ampoules with a capacity of 1 ml to 25 ml. In addition, the machine has a special filling capacity of 0.5 to 25 millilitres in a single dosage. The gadget can fill 25 to 250 ampoules per minute using the volumetric piston-pumps type filling concept. The dead-tray’s availability is another special benefit of this apparatus. It provides ideal diversion of the filled and sealed ampoules.

From cleaning to sealing, ampoules need to be handled precisely. However, pharmaceutical producers often struggle with dependable processing because to tight deadlines, stringent regulations, and delicate containers. With ampoule lines made for safe flame sealing, precise dosing, and gentle handling, Adinath international overcomes this difficulty. We customise every solution to fit your configuration, from small to huge batches, and ensure seamless integration with both upstream and downstream systems.

Salient Features of Ampoule Filler

Compact model as per cGMP standard.
Higher production output up to 12000 Ampoules per hour.
Machine equipped with pre-warming station.
“No Ampoule – No Filling” system.
Flow Meters for regulating flames easily.
Full accessibility allows easy maintenance.

All contact parts made from High Quality Stainless Steel 316L & Non-contact parts made from Stainless Steel 304.
Ampoule neck centering during gas flushing and filling operations.
Minimum change over parts from 1ml to 10ml ampoule size.
Possibility of nitrogen gas flushing before, during and after filling.
Minimum change over time, little maintenance, easy cleaning.

Working Principle of Ampoule Filler

Empty ampoules are placed onto hopper of the machine from where it has been dropped to travelling rack in one/two/four/eight by format part. Ampoules advanced to nitrogen purging stations where inert gas needles flush nitrogen. Further ampoules moves to filling unit where filling needles discharge preset volume of liquid into ampoules. Then ampoules stop at post nitrogen unit where again nitrogen get flush inside the ampule. After filling of ampoules it reaches to the sealing unit which is having pre warming and sealing stations. Pre warming station is having less pressure flame which make ampoule warm up to sealing process. Specially designed rollers rotates ampoules at sealing unit for perfect sealing of ampoules all around. Sealing unit perform sealing operation of ampoules. At last ampoules get collected onto collection tray of the machine in upright position for further processing.

The machine performs the following operations:

Ampoule loading by hopper, star wheel transfers ampoule into transport rack.

One/Two/Four/Six/Eight ampoules advanced each machine stroke.

Centering of ampoules necks during warming, sealing, gas flushing and liquid filling operations.

Rotation of ampoules neck during warming and heating station.

Elimination of waste ampoule tips by clippers and ejection into a separate container.

Technical Specification of Ampoule Filler

Model	AFS-1	AFS-2	AFS-4	AFS-8
No. of Head	Single	Two	Four	Eight
Syringes	One	Double	Four	Eight
Ampoule Sizes	1 ml to 30 ml	1 ml to 30 ml	1 ml to 20 ml	1 ml to 20 ml
Filling Speed	Up to 25 ampoules/minute	Up to 50 ampoules/minute	Up to 100 ampoules/minute	Up to 200 ampoules/minute
Filling Precison	± 1%	± 1%	± 1%	± 1%
Filling Pump	Piston Pump	Piston Pump	Piston Pump	Piston Pump
Burner Gas	LPG & Oxygen (O₂)	LPG & Oxygen (O₂)	LPG & Oxygen (O₂)	LPG & Oxygen (O₂)
Nitrogen Arranegment	Before & After Filling	Before & After Filling	Before & After Filling	Before & After Filling
Number of Fill Nozzles	One	Two	Four	Eight
Number of Nitrogen Nozzles	Two	Four	Eight	Sixteen
Number of Sealing Burners	Two	Four	Eight	Sixteen
Power Required	0.5 H.P.	1 H.P.	1 H.P.	2 H.P.
Power Voltage	230 Volts, Single Phase, 50 Hertz, 4 Wire System	230 Volts, Single Phase, 50 Hertz, 4 Wire System	230 Volts, Single Phase, 50 Hertz, 4 Wire System	230 Volts, Single Phase, 50 Hertz, 4 Wire System
Contact Parts	Made from Stainless Steel 316L	Made from Stainless Steel 316L	Made from Stainless Steel 316L	Made from Stainless Steel 316L
Overall Dimension	915mm (L) x 610mm (W) x 965mm (H) approx.	915mm (L) x 760mm (W) x 965mm (H) approx.	1200mm (L) x 1070mm (W) x 965mm (H) approx.	2200mm (L) x 1400mm (W) x 1100mm (H) 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 Ampoule Filling Machine

Automatic Ampoule Filling Sealing Machine

Laboratory Ampoule Filling Sealing Machine

Closed Ampoule Filling Machine

Open Mouth Ampoule Filling Machine

Onion Skin Ampoule Filling Machine

Single Head Ampoule Filling Machine

Double Head Ampoule Filling Machine

Four Head Ampoule Filling Machine

Six Head Ampoule Filling Machine

Eight Head Ampoule Filling Machine

Applications of Ampoule Filling Machine

Benefits of Ampoule Filler

High-Speed Output: Increases productivity without compromising quality.

Enhanced Accuracy: Maintains consistency in every ampoule filled and sealed.

Operational Safety: Protective features ensure safety for operators and products alike.

Cost Efficiency: Reduces material wastage and utility consumption.

Key Components of Ampoule Filler

1. Infeed and Transport System

Hopper or Infeed Unit: Holds sterilized ampoules (loaded from trays). Ampoules enter via a slant hopper or turntable.
Conveyor Belt / Star Wheel / Rack: Transports ampoules through stations. Many machines use a synchronized star wheel or eccentric rack for precise positioning. Traditional designs move ampoules at a slant (e.g., 45°), while modern ones use vertical travel.
Ampoule Holders / Grippers: Secure ampoules in place during filling and sealing (e.g., self-centering hydraulic grippers).

2. Filling System (Core Dosing Unit)

Reservoir / Filling Source: Stores the liquid product; often refillable and made of stainless steel (AISI 316L for contact parts).
Pumps: Rotary pumps, piston pumps, peristaltic pumps, or servo-controlled systems push liquid from the reservoir. They ensure accurate dosing with minimal shear for sensitive products.
Filling Needles / Catheters / Syringes: Deliver precise volumes into ampoules. Bottom-up filling (with adjustable stroke) is common to reduce foaming or splashing.
Volume Control / Sensors: Regulate fill volume via calibrated mechanisms, valves, or sensors for high accuracy (often ±0.5% or better).

3. Gassing System (for Oxygen-Sensitive Products)

Pre- and Post-Gassing Stations: Flush ampoules with inert gas (e.g., nitrogen) before and after filling to displace oxygen and prevent oxidation or reactions.

4. Sealing System

Pre-Heating and Sealing Heads / Burners: Use flames (gas/oxygen) to melt the ampoule neck tip for hermetic sealing. Includes wire tongs or pulling mechanisms.
Sealing Mechanism: Immediately seals filled ampoules to maintain sterility. Some machines handle pre-sealed or open ampoules.

5. Control and Safety Features

Control Panel / PLC System: Manages speed (via AC frequency drive), filling volume, sequencing, and monitoring. Modern machines use servo-PLC for automation.
Safety Glass / Enclosure: Transparent barriers around the operational area for visibility while preventing contamination and protecting operators.
Laminar Airflow / Cleanroom Compatibility: Maintains Class 100 (ISO 5) conditions in critical zones.

6. Other Supporting Components

Change Parts: Interchangeable star wheels, needles, and racks for different ampoule sizes (e.g., 1ml to 25ml).
Fume Extractor / Exhaust: Removes combustion gases from sealing flames.
Discharge / Outfeed: Collects sealed ampoules into trays or conveyors for further processing (e.g., labeling, inspection).

FAQ for Ampoule Filler

What is an Ampoule Filler Machine?

An Ampoule Filler (also known as Automatic Ampoule Filling and Sealing Machine) is a compact monoblock pharmaceutical machine designed to fill and seal glass ampoules in a single operation. It uses volumetric piston pumps for precise liquid filling and gas burners for sealing. The machine supports nitrogen flushing before, during, and after filling to maintain product stability and is ideal for sterile injectable liquids in the pharmaceutical, biotech, cosmetic, and veterinary industries.

What ampoule sizes and production capacities does your Ampoule Filler support?

Our Ampoule Filler machines handle ampoule sizes from 1 ml to 30 ml (model dependent; e.g., 1-20 ml for multi-head models). Available models include:

Single Head (AFS-1): Up to 25 ampoules/min
Double Head (AFS-2): Up to 50 ampoules/min
Four Head (AFS-4): Up to 100 ampoules/min
Eight Head (AFS-8): Up to 200 ampoules/min (maximum output up to 12,000 ampoules per hour).

Filling precision is ±1%, with special capacity from 0.5 ml to 25 ml in a single dose.

Does the Ampoule Filler support nitrogen flushing and what is the “No Ampoule – No Filling” system?

Yes. The machine is equipped with nitrogen flushing stations for pre-filling, during filling, and post-filling to prevent oxidation and maintain product integrity. It also features a “No Ampoule – No Filling” system that prevents the filling needles from dispensing liquid when an ampoule is missing, reducing product wastage and ensuring cleanliness.

What materials are used in the Ampoule Filler and does it comply with cGMP standards?

All product contact parts are made from high-quality Stainless Steel 316L, while non-contact parts use Stainless Steel 304. The machine is designed as a compact model fully compliant with cGMP standards. It includes full accessibility for easy cleaning and maintenance, minimum change-over parts (especially for 1 ml to 10 ml sizes), and an active pre-heating unit for thick glass ampoules.

How does the Ampoule Filling and Sealing process work?

Empty ampoules are loaded into the hopper and transferred via a star wheel to a traveling rack. They undergo:

Nitrogen purging,
Precise volumetric filling,
Post-nitrogen flushing,
Pre-warming, and
Sealing with rotating rollers using LPG & Oxygen burners for a perfect hermetic seal.

Sealed ampoules are collected upright on a tray (with a dead-tray for diversion). The entire process ensures minimal contamination, gentle handling, and high accuracy.

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