Glass Ampoule Filler

Q: What is the production capacity of the Glass Ampoule Filler?

The production capacity varies by model: AFS-1 (Single Head) : Up to 25 ampoules per minute AFS-2 (Double Head) : Up to 50 ampoules per minute AFS-4 (Four Head) : Up to 100 ampoules per minute AFS-8 (Eight Head) : Up to 200 ampoules per minute This translates to a maximum output of up to 12,000 ampoules per hour on higher models. The speed is adjustable via variable frequency drive, and actual output depends on ampoule size and fill volume.

Description

In accordance with cGMP regulations, the Glass Ampoule Filler (glass ampule filling machine) and glass tube filler are constructed from premium stainless steel 316L. 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.

A machine that can fill seal ampoules with a volume of 1 ml to 30 ml. In addition, the machine has a special filling capacity of 0.5 to 25 millilitres in a single dosage. The gadget can fill 10 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.

Oxygen and LPG (propane) are the gases needed to fill or seal the ampoules. The creation of ampoules containing veterinary medications, cosmetic ampoules, agro-insecticides, and a number of other substances is made as flexible as possible with this cutting-edge device. For all types of open-mouth glass ampoules, our Adinath line of Filler Sealer is ideal.

Salient Features of Glass 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 Glass Ampoule Filler

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 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 Glass Ampoule Filler

Advantages of Glass Ampoule Filler

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 Filler

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 Filler

What is a Glass Ampoule Filler?

The Glass Ampoule Filler (also known as Glass Ampoule Filling and Sealing Machine) is a compact, fully automatic monoblock machine designed to fill and seal open-mouth glass ampoules in one continuous operation. It uses volumetric piston pumps for precise filling and LPG + Oxygen burners for hermetic flame sealing. Available in single, double, four, and eight-head models (AFS-1 to AFS-8), it is ideal for sterile injectable liquids in the pharmaceutical, cosmetic, veterinary, chemical, and biotech industries. All product contact parts are made of high-quality SS 316L and the machine complies with cGMP standards.

What is the production capacity of the Glass Ampoule Filler?

The production capacity varies by model:

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

This translates to a maximum output of up to 12,000 ampoules per hour on higher models. The speed is adjustable via variable frequency drive, and actual output depends on ampoule size and fill volume.

Which ampoule sizes and fill volumes can the Glass Ampoule Filler handle?

The machine supports 1 ml to 30 ml glass ampoules (1 ml to 20 ml on higher-head models). It can 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 minimum change parts, and the machine features neck centering for smooth operation across different ampoule dimensions.

Does the Glass Ampoule Filler support nitrogen flushing for sterility?

Yes. The machine is equipped with pre-, during, and post-nitrogen flushing to remove oxygen, prevent oxidation, and maintain product stability and sterility. It includes dedicated pre and post-nitrogen flushing units. Additional features like the “No Ampoule – No Filling” system, pre-heating station (for thick glass ampoules), and precise flame sealing ensure contamination-free processing suitable for injectable formulations.

What are the key features and benefits of the Glass Ampoule Filler?

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 to eliminate wastage
SS 316L contact parts and cGMP-compliant compact design
Synchronized drives, easy cleaning, low maintenance, and minimum changeover time
Dead tray for diversion of rejected ampoules

Benefits: High-speed sterile filling, excellent dosing precision, reduced product loss, hermetic sealing for longer shelf life, and reliable performance for aqueous or viscous liquids. The machine is easy to operate and maintain, making it suitable for both medium and high-volume production.

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