High Speed Ampoule Filling Machine

Description

The High Speed Ampoule Filling Machine is engineered to handle a wide variety of ampoule neck dimensions and standard thicknesses with exceptional precision. Utilizing advanced slant motion technology during the filling and sealing process, this machine ensures smooth, reliable operation for all standard dimension ampoules, making it highly versatile for pharmaceutical production. Adinath’s High Speed Ampoule Filling and Sealing Machine is built with a sturdy square pipe frame made from premium stainless steel alloy, complete with full S.S. coverings. Its elegant matt finish not only enhances durability but also supports high-level productivity in demanding manufacturing environments. For added operator convenience and safety, the electrical control panel is designed in a user-friendly pendant style, positioned away from the main machine.

The High Speed Ampoule Filling Machine is designed for accurate dosing of injectable liquids ranging from 0.5 ml to 10 ml in a single operation. While primarily built for open-mouth ampoules, it also supports closed-mouth ampoules, offering excellent flexibility for pharmaceutical manufacturers. This advanced Ampoule Filling and Sealing Machine features multiple filling options including Peristaltic Pump Filling, Servo-Controlled Filling, and Piston Pump Filling systems. Its integrated sealing unit performs two-stage operations: preheating to eliminate any residual droplets inside the ampoule, followed by precise sealing using LPG and oxygen gas with a 360-degree flame for strong, uniform seals. The machine uses a slanted rack movement system that smoothly transports ampoules through critical stages — nitrogen purging, liquid filling, preheating, and sealing. A smart No Ampoule – No Fill system prevents liquid wastage by ensuring filling needles only operate when an ampoule is present.

Salient Features of High Speed Ampoule Filling Machine

Compact cGMP model.
Higher 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 High Speed 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 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.

Loading: Sterilized ampoules are loaded into a slant hopper and fed via a starwheel to a transport rack.

Pre-Gassing: Nitrogen is flushed to displace oxygen.

Filling: Precise liquid dosing using piston or peristaltic pumps, with neck centering for accuracy.

Post-Gassing: Additional nitrogen flushing to ensure sterility.

Pre-Heating: Low-flame heating prepares the ampoule neck for sealing.

Sealing: High-flame or laser sealing forms an airtight closure, with waste glass removed by clippers.

Collection: Filled and sealed ampoules are automatically collected in upright trays for inspection or labeling.

Technical Specification of High Speed Ampoule Filling Machine

Model Name	AFS-8
Production Speed	Up to 200 ampules/minute
Ampoule Sizes	1 ml to 20 ml
Filling Error	± 1%
Sealing Gas	LPG and Oxygen (O₂)
Nitrogen Gas	Pre & Post Nitrogen
Power Load	2 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	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

Advantages of High Speed Ampoule Filling Machine

High Precision: Fill accuracy of ±0.5% ensures consistent dosing.

Sterility: Aseptic conditions minimize contamination risks.

Efficiency: High-speed operation (up to 30,000 ampoules/hour for advanced models like Syntegon’s ALF 4000) and minimal changeover time.

Versatility: Handles various ampoule sizes and materials (glass/plastic).

Automation: Reduces manual labor, errors, and operational costs.

Key Features of High Speed Ampoule Filling Machine

Output Capacity: Ranges from 80 to 300 ampoules per minute, depending on the model and number of filling heads (e.g., single, two, four, six, or eight heads). For instance, an eight-head machine can achieve up to 12,000 ampoules per hour for 1-10ml sizes.

Filling Volume: Adjustable from 0.5ml to 30ml, accommodating ampoule sizes of 1ml to 30ml.

Filling Mechanisms: Options include:
- Piston Pumps (volumetric, for precise dosing).
- Peristaltic Pumps (ideal for sterile applications, adjustable via touch-screen in servo-driven models).
- Servo-Driven Systems (offer zero mechanical adjustments and high precision).

Sealing Process: Typically involves a two-stage process:

1. Pre-heating: Low-flame heating to remove liquid droplets from the ampoule’s inner surface.
2. Sealing: Uses oxygen-LPG or thermal/laser methods to melt glass for an airtight seal, often with 360° ampoule rotation for uniform dome-shaped sealing.

Automation: Fully automatic models minimize human intervention, reducing contamination risks. Features include:

- In-feed Hopper and Starwheel: For automatic ampoule loading and transport.
- Pre- and Post-Gassing: Nitrogen flushing to remove oxygen and extend shelf life.
- No-Ampoule-No-Fill Safety: Prevents liquid spillage.
- PLC/HMI Control: For precise fill volume adjustments and operational ease.

Construction: Built with stainless steel 316L for contact parts and 304 for non-contact parts, ensuring durability and compliance with cGMP standards.

Versatility: Handles open-mouth and closed-mouth ampoules, with tool-less format changes for different sizes. Suitable for liquids, powders, and pellets.

Hygienic Design: Enclosed systems with laminar flow compatibility and easy-to-clean surfaces for sterile environments.

FAQ for High Speed Ampoule Filling Machine

What is a High Speed Ampoule Filling Machine?

The High Speed Ampoule Filling Machine (Model AFS-8 – Eight Head) is a fully automatic, compact monoblock cGMP-compliant machine designed for high-volume filling and hermetic sealing of glass ampoules. It processes up to eight ampoules simultaneously using a slant travelling mechanism, volumetric piston pumps for precise filling, and LPG + Oxygen flame sealing. It supports pre-, during, and post-nitrogen flushing with ampoule neck centering, making it ideal for sterile injectable liquids in the pharmaceutical, biotech, veterinary, cosmetic, and chemical industries.

What is the production capacity of the High Speed Ampoule Filling Machine?

This high-speed model delivers an output of up to 200 ampoules per minute (approximately 12,000 ampoules per hour). For smaller sizes like 1 ml and 2 ml, it can achieve even higher speeds of 240–290 ampoules per minute depending on configuration. The speed is adjustable via variable frequency drive, and actual output depends on ampoule size, fill volume, and product viscosity. It is one of the fastest options for large-batch sterile production.

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

The machine handles 1 ml to 20 ml glass ampoules (with support for 0.5 ml to 30 ml in certain setups). It can fill volumes ranging from 0.5 ml to 25 ml (up to 30 ml) in a single dose with ±1% filling accuracy (some configurations achieve ±0.5%). Minimum changeover parts and quick format change make it easy to switch between sizes with very little downtime.

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

Yes. It features advanced pre-, during, and post-nitrogen flushing with ampoule neck centering to remove oxygen, prevent oxidation, and maintain product stability and sterility. Additional sterile features include a “No Ampoule – No Filling” interlock system to eliminate wastage, a pre-heating station, and precise 360° flame sealing for uniform, leak-proof seals. All product contact parts are SS 316L, and the machine is fully cGMP compliant, suitable for Class 100 cleanroom environments.

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

Key features include:

Eight-head high-speed design with synchronized drives
Volumetric piston pump filling with ±1% accuracy
Multi-stage nitrogen flushing (pre, during & post) with neck centering
Pre-heating station and accurate LPG + Oxygen flame sealing with flow meters
“No Ampoule – No Filling” system and dead tray for rejected ampoules
SS 316L contact parts and compact cGMP-compliant monoblock design
Minimum changeover time, easy cleaning, and low maintenance

Benefits: Extremely high output for large-scale production, superior filling precision, excellent sterility assurance, reduced product wastage, hermetic sealing for longer shelf life, and lower labor costs. Optional PLC + HMI, servo filling, and peristaltic pumps are also available.

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