Two Head Ampoule Filling & Sealing Machine

Q: How does the Two Head Ampoule Filling & Sealing Machine work?

The machine works on the slant (angle travel) movement principle . Pre-sterilized ampoules are fed from the hopper into a moving rack in groups of two. They then pass through synchronized stations: Pre-gassing with nitrogen flushing and neck centering Precise volumetric filling using two heads (with diving nozzles for foam-free filling) Post-gassing with nitrogen (before, during, or after filling) Pre-warming and two-stage flame sealing using LPG + Oxygen while ampoules rotate for a uniform hermetic seal Filled and sealed ampoules are collected upright in a dead tray. It includes a “No Ampoule – No Filling” system and automatic sensors to prevent wastage and ensure accuracy.

Description

Two Head Ampoule Filling & Sealing Machine is a precision-engineered solution designed for the accurate filling and flame sealing of open-mouth glass ampoules in sterile pharmaceutical manufacturing. Engineered to maintain the highest levels of sterility and accuracy, this machine is an essential asset for production lines requiring consistent, high-speed output with minimal wastage. Developed by Adinath International, a trusted manufacturer of pharmaceutical processing equipment, this machine combines advanced engineering, durable construction, and reliable automation to deliver consistent performance for small- to medium-scale production. It is widely used in the pharmaceutical, biotechnology, cosmetic, chemical, veterinary, and research industries where precision, product safety, and operational efficiency are essential. Designed to handle 1 ml to 25 ml open-mouth glass ampoules, the machine offers a filling capacity ranging from 0.5 ml to 25 ml using an efficient dual-head filling and sealing system. This configuration enables faster production while maintaining exceptional filling accuracy for sterile liquid formulations, injectable medicines, vaccines, laboratory reagents, cosmetic serums, and specialty chemical products. Depending on the ampoule size and product characteristics, the machine delivers an output of approximately 30 to 40 ampoules per minute, making it an ideal choice for pilot plants, research laboratories, contract manufacturing units, and pharmaceutical production facilities.

The Automatic Two Head Ampoule Filling Machine operates on the proven slant travel principle, allowing ampoules to move smoothly during the filling and sealing process. This innovative operating mechanism compensates for variations in ampoule neck diameter, wall thickness, and glass ovality, ensuring accurate filling volumes and consistent flame sealing across different ampoule specifications. The result is improved product quality, reduced rejection rates, and enhanced manufacturing efficiency, even when processing ampoules from different suppliers. Manufactured using premium-quality stainless steel, the Glass Ampoule Filling and Sealing Machine is designed for durability, corrosion resistance, and hygienic operation. Its robust construction minimizes wear and maintenance requirements, making it suitable for continuous production environments. All critical components are precision engineered to provide long service life while supporting compliance with Good Manufacturing Practices (GMP). The smooth stainless steel surfaces are easy to clean and sanitize, helping manufacturers maintain contamination-free production conditions required for sterile pharmaceutical products.

A single synchronized motor drives all major machine functions, ensuring seamless coordination between ampoule feeding, transfer, filling, heating, nitrogen purging, and sealing operations. This synchronized motion enables smooth ampoule rotation at the sealing station, resulting in uniform and secure sealing performance. The integrated automatic sensing system further enhances operational reliability through its intelligent “No Ampoule, No Filling” feature. If an ampoule is not detected in the filling position, the system immediately stops the filling cycle, preventing unnecessary product loss and ensuring efficient use of valuable pharmaceutical formulations. Backed by years of experience in pharmaceutical equipment manufacturing, Adinath International offers both standard and fully customized Ampoule Filling and Sealing Machines to meet specific customer production requirements. Our experienced engineering team works closely with clients to develop tailored solutions that align with unique filling capacities, container specifications, and production objectives.

Salient Features of Ampoule Filling & Sealing Machine

Compact model as per cGMP standard.
Higher output up to 3000 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 Two Head Ampoule Filling & Sealing Machine

Empty washed & sterilized ampoules receive automatically on wire mesh conveyor belt from outfeed of sterilizing tunnel. Ampoule fed automatically into in-feed hopper from the left hand side of the machine and feed to receiving rack through cassette. The moving rack which moves horizontally collect two ampoules from the receiving rack and transfer the ampoule to the machine in left to right in an inclined position through pre-gassing. Pre-gassing, Filling, Post Gassing, Pre-heating & sealing sta.

Technical Specification of Two Head Ampoule Filling & Sealing Machine

Model Name	AFS-2
Production Speed	Up to 50 ampules/minute
Ampoule Sizes	1 ml to 30 ml
Filling Error	± 1%
Sealing Gas	LPG and Oxygen (O₂)
Nitrogen Gas	Pre & Post Nitrogen
Power Load	0.5 H. P.
Power Voltage	230 Volts, Single Phase, 50 Hertz
Contact Parts	Made from Stainless Steel 316L
Non-Contact Parts	Made from Stainless Steel 304
Machine Size	915mm (L) x 760mm (W) x 965mm (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 Two Head Ampoule Filling & Sealing Machine

High precision and efficiency with minimal product loss.

Compact design requiring less floor space, ideal for small to medium-scale facilities.

Customizable filling mechanisms (piston, servo, or peristaltic) to meet specific needs.

Robust, durable construction for long-term use with minimal upkeep.

Energy-efficient with automated features to streamline production.

Key Features of Two Head Ampoule Filling & Sealing Machine

Construction: Made with a stainless steel (SS) square pipe frame and SS 316L contact parts for durability and compliance with cGMP standards. Non-contact parts are typically SS 304, with a matte finish for aesthetic appeal and ease of cleaning.

Filling Capacity: Suitable for filling 1ml to 25ml ampoules, with a dosing range of 0.5ml to 25ml per cycle. It operates using volumetric piston pumps, servo-driven pumps, or peristaltic pumps, depending on customization.

Output: Capable of filling 30 to 90 ampoules per minute (approximately 1,800 to 5,400 ampoules per hour), ideal for small to medium-scale production.

Operation: Fully automatic with minimal human intervention. Ampoules are loaded into an in-feed hopper, transferred via a synchronized star wheel to a transport rack, and moved through sequential stations:
- Pre-Nitrogen Flushing: Inert gas (nitrogen) is flushed to reduce oxygen exposure.
- Filling: Two filling heads discharge precise liquid volumes, with neck centering for accuracy.
- Post-Nitrogen Flushing: Additional nitrogen flush to maintain sterility.
- Pre-Heating: A low-pressure flame warms ampoules for sealing.
- Sealing: Uses oxygen and LPG (propane) with specially designed rollers for uniform sealing of open or closed-type ampoules (Type B and C).

Sealing Process: Features a two-stage sealing system (pre-heating and final sealing) to ensure clean, precise seals. Waste tips are collected in a high-quality SS container.

Flexibility: Minimal changeover parts required for different ampoule sizes (1ml to 20ml or 30ml, depending on the model). Format parts can be changed by hand without tools.

Control System: Equipped with a user-friendly touchscreen interface for adjusting fill volume, speed, and sealing temperature. Some models include PLC-based controls for automated fill volume adjustments and an automatic stop function to prevent accidents and reduce wastage.

Maintenance: Designed for low maintenance with easy-clean features, including a large bottom opening for access. Stainless steel construction ensures corrosion resistance and sterility.

Safety and Compliance: Complies with GMP and CE standards. Optional safety cabinets, laminar airflow, or isolators can be integrated for sterile Class 100 filling. Energy-saving features, such as automatic shut-off when idle, reduce operational costs.

Additional Features:
- Dead tray for upright ampoule collection.
- Pre-warming station for thick glass ampoules to ensure perfect sealing.
- Adjustable ampoule loading tray for handling various sizes.
- Optional servo-driven or peristaltic pump for enhanced precision and sterility.

FAQ for Two Head Ampoule Filling & Sealing Machine

What is a Two Head Ampoule Filling & Sealing Machine?

A Two Head Ampoule Filling & Sealing Machine (Model AFS-2), also known as Double Head or Double Stroke Ampoule Filler, is a compact, fully automatic machine designed for filling and hermetically sealing glass ampoules with sterile liquids such as injectables, vaccines, antibiotics, and serums. It features two filling heads that operate simultaneously, making it ideal for small to medium-scale production in pharmaceutical, biotech, and cosmetic industries while maintaining high sterility and cGMP compliance.

What is the production capacity and ampoule size range of the Two Head Ampoule Filling Machine?

The Two Head Ampoule Filling and Sealing Machine offers an output of up to 50 ampoules per minute (approximately 3,000 ampoules per hour). It can handle 1 ml to 30 ml glass ampoules with a filling range of 0.5 ml to 25 ml in a single dose. Minimum changeover parts are required for sizes from 1 ml to 10 ml, allowing quick format changes with excellent flexibility for different batch sizes.

How does the Two Head Ampoule Filling & Sealing Machine work?

The machine works on the slant (angle travel) movement principle. Pre-sterilized ampoules are fed from the hopper into a moving rack in groups of two. They then pass through synchronized stations:

Pre-gassing with nitrogen flushing and neck centering
Precise volumetric filling using two heads (with diving nozzles for foam-free filling)
Post-gassing with nitrogen (before, during, or after filling)
Pre-warming and two-stage flame sealing using LPG + Oxygen while ampoules rotate for a uniform hermetic seal

Filled and sealed ampoules are collected upright in a dead tray. It includes a “No Ampoule – No Filling” system and automatic sensors to prevent wastage and ensure accuracy.

What are the key features and benefits of the Two Head Ampoule Filling & Sealing Machine?

Key features include:

Two filling heads for higher output in a compact footprint
“No Ampoule – No Filling” system with neck centering
Pre & post nitrogen flushing facility (before, during, and after filling)
Pre-warming station and flow meters for easy flame regulation
High filling accuracy of ±1% (optimizable to ±0.5%)
Contact parts in SS 316L and non-contact parts in SS 304
Compact cGMP model with full accessibility and easy cleaning
Low power consumption (0.5 HP) and minimum changeover time

Benefits: It provides a perfect balance between speed and space, reduces product wastage, ensures superior sterility, requires minimal labor and maintenance, and is highly suitable for medium-batch injectable manufacturing.

What are the technical specifications and compliance standards for the Two Head Ampoule Filling Machine?

The machine requires LPG & Oxygen for sealing and supports nitrogen gas flushing. Power load is 0.5 H.P. (230 Volts, Single Phase, 50 Hz – customizable). It is fully cGMP and CE compliant, with easy-to-clean design and low maintenance. It can be integrated with laminar airflow for sterile (Class 100) operation. We provide detailed operation manuals, operator training, and reliable after-sales support with spare parts availability to ensure minimal downtime and long-term performance.

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