Four Head Ampoule Filling and Sealing Machine

Description

Adinath International is a leading manufacturer and exporter of the Four Head Ampoule Filling and Sealing Machine. This advanced four head ampoule filler and sealer is constructed from premium 316L Stainless Steel and fully complies with cGMP standards, making it ideal for pharmaceutical and injectable production. The machine features synchronized drives powered by a single motor with variable speed control. It is equipped with both pre- and post-nitrogen flushing systems for enhanced product stability. An active pre-heating unit is also included, allowing smooth handling of thick glass ampoules. This automatic four head ampoule filling machine supports filling volumes from 0.5 ml to 25 ml in a single dose and can process 1 ml to 10 ml ampoules at speeds of 60 to 100 ampoules per minute using a precise volumetric piston pump filling system. It uses LPG (propane) and Oxygen for reliable sealing and includes a convenient dead tray for filled and sealed ampoules. Suitable for a wide range of applications, including pharmaceutical injectables, cosmetic products, veterinary medicines, and agrochemicals, this robust ampoule filling and sealing machine is the preferred choice for manufacturers seeking accuracy, efficiency, and durability.

Adinath International offers a highly customizable Four Head Ampoule Filling and Sealing Machine built with premium-quality components for superior performance and durability. All product contact parts are made from SS AISI 316L, while non-contact parts use SS AISI 304, ensuring full compliance with GMP standards. This automatic four head ampoule filler and sealer delivers a production output of 60 to 90 ampoules per minute. It operates on the proven slant travel principle, allowing it to efficiently handle a wide variety of injectable liquids while accommodating variations in ampoule neck dimensions, thickness, and sizes.

The machine features an advanced rectangular feeding system along with automatic ampoule feeding, transfer, nitrogen flushing, filling, pre-heating, and sealing operations. It includes a reliable “No Ampoule – No Filling” system that prevents liquid wastage and improves overall efficiency. With a filling accuracy of ±1%, it ensures consistent and precise dosing. Designed on a sturdy S.S. square pipe frame with full matt-finish stainless steel coverings, the machine offers excellent accessibility for cleaning and maintenance through a large bottom aperture. The detached pendant-style electrical control panel enhances operator safety and convenience.

Salient Features of Four Head Ampoule Filling Machine

Compact cGMP model.
Higher output up to 6000 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 Four Head Ampoule Filling and Sealing 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.

Ampoule Loading: Sterilized ampoules are loaded into the infeed hopper and transferred via a starwheel or cassette to a traveling rack in groups of four.

Pre-Nitrogen Flushing: Nitrogen is flushed to remove air and maintain sterility.

Filling: Four filling needles dispense the precise volume of liquid into the ampoules.

Post-Nitrogen Flushing: Additional nitrogen flushing to protect the filled liquid.

Pre-Heating: A low-pressure flame prepares the ampoule for sealing by removing droplets.

Sealing: Ampoules are sealed using LPG/oxygen flames, with rollers ensuring uniform sealing.

Collection: Filled and sealed ampoules are automatically collected in a tray or dead tray without manual handling.

Technical Specification of Four Head Ampoule Filling and Sealing Machine

Model Name	AFS-4
Production Speed	Up to 100 ampules/minute
Ampoule Sizes	1 ml to 10 ml
Filling Error	± 1%
Sealing Gas	LPG and Oxygen (O₂)
Nitrogen Gas	Pre & Post Nitrogen
Power Load	1 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	1200mm (L) x 1070mm (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 Four Head Ampoule Filling and Sealing Machine

High Efficiency: High-speed operation with minimal downtime and waste.

Sterility and Compliance: cGMP-compliant design with SS 316L contact parts and nitrogen flushing for sterile filling.

Versatility: Handles a wide range of ampoule sizes and liquid types, with customizable filling mechanisms.

Low Maintenance: Robust construction and minimal changeover parts reduce maintenance needs.

User-Friendly: Simplified controls, tool-less adjustments, and accessible design for ease of use.

Key Features of Four Head Ampoule Filling and Sealing Machine

Construction and Materials:
1. Frame: Built on a sturdy stainless steel (SS) square pipe frame, often encased in SS 304 coverings with a matte finish for aesthetic appeal and durability.
2. Contact Parts: Made from high-quality SS 316L to ensure compatibility with injectable liquids and maintain sterility.
3. Non-Contact Parts: Typically constructed from SS 304, mild steel, or brass, depending on the manufacturer.
4. Vibration-Free Design: Incorporates cam mechanisms or synchronized motors to minimize vibrations during operation, ensuring smooth ampoule handling.

Filling Capacity:
1. Capable of filling ampoules ranging from 0.5 ml to 25 ml in a single dose, depending on the model.
2. Production output ranges from 50 to 250 ampoules per minute, with some models achieving up to 6,000 ampoules per hour for medium-scale production.

Filling Mechanisms:
1. Offers multiple filling options to suit different liquid viscosities and production needs:
  1. Piston Pump Filling: Ideal for consistent dosing of liquids.
  2. Servo-Driven Filling: Enhances precision and allows adjustments via touch-screen controls.
  3. Peristaltic Pump Filling: Ensures sterile and smooth filling, particularly for sensitive liquids.
2. Filling accuracy is typically ±1%, ensuring minimal wastage and high precision.

Nitrogen Flushing:
1. Equipped with pre- and post-nitrogen flushing nozzles to maintain product sterility by preventing oxidation and contamination.
2. Nitrogen purging occurs before and after filling to protect the liquid from environmental exposure.

Sealing Process:
1. Features a two-stage sealing unit:
  1. Pre-Heating Stage: Uses a low-pressure flame to warm the ampoule and remove residual droplets, ensuring clean sealing.
  2. Sealing Stage: Employs LPG (propane) and oxygen or gas burners to seal the ampoule, with rollers rotating the ampoule for a uniform 360-degree seal.
2. Some models include a waste tip collector made of SS for safe disposal of glass remnants.

Ampoule Handling:
1. Slant Travel Mechanism: Ampoules move on an inclined rack or via a synchronized starwheel, ensuring precise neck centering during filling, gas flushing, and sealing.
2. No Ampoule, No Fill System: Automatically stops liquid discharge if no ampoule is present, reducing waste and enhancing efficiency.
3. Capable of handling both open-mouth and closed-mouth ampoules (with specific models for each).

Ease of Operation and Maintenance:
1. Minimal Changeover Time: Requires minimal changeover parts for ampoule sizes from 1 ml to 10 ml, and some models support up to 25 ml with quick adjustments.
2. Tool-Less Format Changes: Simplifies switching between ampoule sizes without specialized tools.
3. Accessible Design: Features large openings at the bottom for easy cleaning and maintenance.
4. Pendant-Type Control Panel: Lifted from the machine for safe and user-friendly operation.

Optional Features:
1. PLC with Touch Screen HMI: For precise control and fill volume adjustments.
2. Variable Frequency Drive (VFD): Allows easy speed regulation.
3. Laminar Air Flow or Safety Cabinet: Ensures a sterile Class 100 environment for filling.
4. Servo-Based Filling Systems: For enhanced accuracy and automation.
5. Blower for Flame Heat: Directs heat away from the sterile room.

FAQ for Four Head Ampoule Filling and Sealing Machine

What is a Four Head Ampoule Filling and Sealing Machine?

The Four Head Ampoule Filling and Sealing Machine (Model AFS-4) is a compact, fully automatic cGMP-compliant machine designed to fill and seal 1 ml to 10 ml ampoules at high speed. It uses a volumetric piston pump for precise liquid filling, supports pre- and post-nitrogen flushing, and seals ampoules using LPG and oxygen flames. Ideal for sterile injectable liquids in the pharmaceutical, cosmetic, veterinary, and chemical industries.

What is the production capacity of the Four Head Ampoule Filling and Sealing Machine?

This machine can process 60 to 100 ampoules per minute, which translates to approximately 3600 to 6000 ampoules per hour. The exact output depends on ampoule size, fill volume (0.5 ml to 25 ml single dose), and product viscosity. It features a variable speed drive for easy adjustment according to your production requirements.

Which ampoule sizes can the machine handle, and how accurate is the filling?

The Four Head Ampoule Filling and Sealing Machine handles 1 ml to 10 ml ampoules as standard (with support for 0.5 ml to 25 ml fill volumes). Filling accuracy is ±1%, achieved through a high-precision volumetric piston pump and ampoule neck centering during flushing and filling. Minimum changeover parts and quick adjustments make it easy to switch between different sizes.

Does the machine support nitrogen flushing and sterile operation?

Yes. It comes equipped with pre- and post-nitrogen flushing units to remove oxygen and maintain product stability and sterility. The machine also includes a pre-heating station and a “No Ampoule – No Filling” system that prevents wastage and contamination. All product contact parts are made of SS 316L, and the design fully complies with cGMP standards, making it suitable for injectable and sensitive formulations.

What are the key features and benefits of this machine?

Key features include:

Compact cGMP model with SS 316L contact parts
“No Ampoule – No Filling” system
Pre-warming station and precise flame sealing with flow meters
Slant travelling mechanism for smooth operation
Low maintenance, easy cleaning, and minimal changeover time
Pendant-type control panel

Benefits: High efficiency, reduced product waste, excellent filling accuracy, sterile processing, and reliable performance for medium-to-high volume production. Optional accessories like PLC/HMI, servo filling, and laminar airflow are also available.

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