Glass Ampoule Filling Machine

Q: What is the production capacity of the Glass Ampoule Filling Machine?

Production capacity depends on the model: AFS-1 (Single Head) : Up to 25 ampoules/min AFS-2 (Double Head) : Up to 50 ampoules/min AFS-4 (Four Head) : Up to 100 ampoules/min AFS-8 (Eight Head) : Up to 200 ampoules/min This gives a maximum output of up to 12,000 ampoules per hour . Speed is adjustable via variable frequency drive, and actual output varies with ampoule size, fill volume, and product viscosity.

Description

The pharmaceutical and cosmetic industries utilise an advanced piece of machinery called a Glass Ampoule Filling Machine to fill and seal glass ampoules. Medications, vaccines, and other liquid pharmaceuticals are filled and sealed with it. To preserve sterility and avoid contamination, the sealing procedure guarantees that the ampoules are hermetically sealed. Small, sealed vials called ampoules are used to hold and retain sterile substances like serums or drugs. Glass ampoule filling machines can frequently be altered or adjusted to handle a variety of ampoule sizes and types, meeting a range of product needs.

Filling and sealing machines for open or closed ampoules that can produce 2,000–12,000 pieces per hour are included in this machine category. These machines ensure flawlessly reproducible and sanitary filling and sealing processes. These machines have a long-standing reputation for dependability and exceptionally excellent quality because of its simple size changeover, filling unit with easy disassembly and sterilisation, and simple integration of a high-performance laminar flow system.

1 ml to 20 ml glass ampoules can be filled and drawn sealed using the glass ampoule filling and sealing equipment. From bottle feeding, nitrogen filling, liquid filling, preheating, draw closing, and final bottle discharging, it can all be done automatically. The device can be used alone or in conjunction with a sterilising drying machine and an ultrasonic cleaning machine.

The most tried-and-true module and the idea of slant travelling of ampoules during the filling and sealing of ampoules through the Ampoule Filling Machine served as the foundation for the construction of the Glass Ampoule Filling Sealing Machine. This is done to make sure that all types of ampoules that differ from one another in terms of thickness, size, or any other variation are filled and sealed with the greatest level of resource optimisation.

Salient Features of Glass Ampoule Filling Machine

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 Glass Ampoule Filling Machine

Empty washed & sterilized ampoules loaded onto infeed hopper of the machine. From where it has been received to receiving rack through starwheel/cassette. The moving rack which moves horizontally collect one/two/four/eight ampoules from the receiving rack and transfer the ampoule to the machine in left to right in an inclined position. During ampoule movement Pre-gassing, Filling, Post Gassing, Pre-heating & Sealing Station perform filling and sealing operations. At the end duly filled and sealed ampoules get collected automatically onto collection tray of the machine.

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 Glass Ampoule Filling Machine

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 Glass Ampoule Filling Machine

Advantages of Glass Ampoule Filling Machine

Precision and Accuracy: Ensures exact dosing, critical for pharmaceuticals to avoid over- or under-dosing.

Sterility: Hermetic sealing and nitrogen flushing protect contents from contaminants, extending shelf life.

Efficiency: High-speed automation reduces labor and increases output.

Durability: Stainless steel construction ensures long-term reliability and easy maintenance.

Flexibility: Handles various ampoule sizes and liquid types (aqueous, viscous, or powders).

Key Features of Glass Ampoule Filling Machine

Functionality: These machines automate the process of filling glass ampoules with liquids (or sometimes powders/pellets) and sealing them, typically using a flame to melt the glass for hermetic sealing. Some models also include nitrogen purging to remove atmospheric air and prevent contamination.

Capacity and Speed: Machines vary in output, ranging from 15 to 36,000 ampoules per hour, depending on the model (e.g., single-head for lab-scale or eight-head for high-speed production). Fill volumes typically range from 0.2 ml to 30 ml.

Design: Built with stainless steel (often AISI 316L for contact parts and AISI 304 for non-contact parts) for durability and compliance with cGMP standards. Monoblock designs combine filling and sealing on a single platform for efficiency.

Filling Mechanisms: Common mechanisms include volumetric piston pumps, peristaltic pumps, or servo-driven systems for precise filling. Some feature “no ampoule, no fill” systems to prevent wastage.

Sealing Process: Typically involves pre-heating, gas flushing (oxygen and LPG/propane), and final sealing with a flame. Ampoule necks are centered and rotated during sealing for uniformity.

Additional Features:
- Nitrogen flushing (pre- and post-filling) to ensure sterility.
- PLC systems and HMI for real-time monitoring and error detection.
- Easy changeover for different ampoule sizes (1 ml to 30 ml) with minimal parts.
- Slant travel mechanism to accommodate variations in ampoule neck dimensions, thickness, and ovality.
- Waste tip collection and rejection systems for faulty ampoules.

FAQ for Glass Ampoule Filling Machine

What is a Glass Ampoule Filling Machine?

The Glass Ampoule Filling Machine (Models AFS-1, AFS-2, AFS-4 & AFS-8) is a fully automatic, monoblock cGMP-compliant machine designed to fill and hermetically seal glass ampoules in one continuous operation. It uses volumetric piston pumps for precise liquid filling and LPG + Oxygen flame sealing. The machine features a slant travelling mechanism, neck centering, and nitrogen flushing (pre-, during & post-filling) to ensure sterility and prevent oxidation. It is ideal for sterile injectable liquids, vaccines, serums, and other pharmaceutical, cosmetic, veterinary, and biotech products.

What is the production capacity of the Glass Ampoule Filling Machine?

Production capacity depends on the model:

AFS-1 (Single Head): Up to 25 ampoules/min
AFS-2 (Double Head): Up to 50 ampoules/min
AFS-4 (Four Head): Up to 100 ampoules/min
AFS-8 (Eight Head): Up to 200 ampoules/min

This gives a maximum output of up to 12,000 ampoules per hour. Speed is adjustable via variable frequency drive, and actual output varies with ampoule size, fill volume, and product viscosity.

Which ampoule sizes and fill volumes does the Glass Ampoule Filling Machine support?

The machine handles 1 ml to 30 ml glass ampoules (1 ml to 20 ml on higher-head models). It supports fill volumes from 0.5 ml to 25 ml in a single dose with ±1% filling accuracy. Changeover between sizes (especially 1 ml to 10 ml) requires minimal parts, thanks to the neck centering system and slant travelling mechanism that accommodates variations in ampoule thickness and ovality.

Does the Glass Ampoule Filling Machine support nitrogen flushing and sterile operation?

Yes. It is equipped with pre-, during, and post-nitrogen flushing to remove oxygen, maintain product stability, and ensure sterility. Additional features include a “No Ampoule – No Filling” system to prevent wastage, a pre-heating station for thick glass ampoules, and precise flame sealing. All product contact parts are SS 316L, and the machine is fully cGMP compliant, making it suitable for sensitive injectable formulations.

What are the key features and benefits of the Glass Ampoule Filling Machine?

Key features include:

Volumetric piston pump filling with ±1% accuracy
Nitrogen flushing before, during, and after filling
Pre-heating station and accurate LPG + Oxygen flame sealing with flow meters
“No Ampoule – No Filling” system and dead tray for rejected ampoules
Slant travelling mechanism with ampoule neck centering
SS 316L contact parts and compact cGMP design
Easy cleaning, low maintenance, and minimum changeover time

Benefits: High-speed sterile production, excellent dosing precision, hermetic sealing for longer shelf life, reduced product wastage, and reliable performance across various liquid viscosities. Optional laminar airflow, PLC/HMI, and integration with washing/sterilizing lines are also available.

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