Injectable Powder Filler, also known as an Injectable Bottle Powder Filling Machine or Dry Powder Vial Filling Machine, is specialized pharmaceutical equipment engineered for the accurate, sterile filling of dry powders into glass bottles and vials. Designed specifically for injectable formulations such as antibiotics, vaccines, lyophilized products, and other moisture-sensitive medicines, this machine plays a critical role in modern aseptic manufacturing environments where consistency, sterility, and regulatory compliance are essential.
In pharmaceutical production, liquid injectables are not always stable for long-term storage. Many potent APIs require dry powder form to maintain efficacy and extend shelf life. The Injectable Powder Filler addresses this need by delivering precise doses of free-flowing or semi-free-flowing powders under controlled conditions. Typical fill ranges start from a few grams upward, with models achieving filling accuracy of ±2% when humidity is maintained below 28% RH. This level of precision supports dosage uniformity, reduces costly product rejects, and helps manufacturers meet stringent regulatory expectations for injectable medicines.
Built as a monoblock cGMP-compliant system, the machine incorporates advanced features that prioritize hygiene and operational safety. Product-contact parts are constructed for easy removal, enabling thorough cleaning, autoclaving, and sterilization between batches. The main machine body is typically fabricated from SS304 stainless steel, while contact surfaces meet the highest cleanliness standards. A unique vibratory funnel system combined with rotary bottle handling ensures high-speed filling of semi-free-flowing powders without compromising accuracy. The “No Bottle – No Fill” interlock system, automatic machine stop on low air or low vacuum, and toughened-glass safety cabinet further protect both product and operators.
The working principle is straightforward yet highly controlled. Sterilized dry bottles enter through an in-feed turntable and are guided onto a flat conveyor. When a bottle reaches the mechanical holder at the filling station, a sensor activates the magnetic clutch mounted on the auger shaft. The auger rotates for a pre-determined time to dispense the exact quantity of powder. Filled bottles are then transferred via a stainless-steel conveyor to the sealing or stoppering station. Automatic infeed and outfeed through star-wheel systems, tool-free adjustment of doctor and wiper blades, and servo or frequency-drive control contribute to smooth, efficient operation with minimal downtime.
Key benefits of an Injectable Powder Filler include high filling accuracy, reduced powder wastage, strong contamination control, and improved production throughput (commonly 80–120 bottles per minute depending on model and fill volume). Quick changeover capability and modular design support multiple bottle sizes and fill weights, making the equipment versatile for diverse product portfolios. Integration with upstream washing and sterilization equipment and downstream stoppering, capping, and inspection systems allows manufacturers to create complete sterile powder filling lines.
From an operational and compliance perspective, these machines are developed with deep industry experience in aseptic processing. Features such as oil-free gearboxes, clutch protection, and compatibility with isolator or RABS environments demonstrate technical expertise and commitment to current Good Manufacturing Practices. Pharmaceutical companies worldwide rely on such systems because they combine proven mechanical reliability with the process control needed for regulated injectable production. Whether you are scaling antibiotic manufacturing, producing lyophilized injectables, or seeking a compact monoblock solution for sterile dry powder filling, an Injectable Powder Filler delivers the accuracy, hygiene, and efficiency required in today’s pharmaceutical industry. Choosing equipment designed to cGMP standards with robust safety interlocks and easy-maintenance construction provides long-term trustworthiness and supports consistent, high-quality output for patients who depend on sterile injectable medicines.
Sterilized powder stored in the powder hopper is continuously agitated by a pair of mechanical agitators to maintain consistent flow and uniform bulk density. A powder wheel with twelve ports rotates at a pre-set speed directly beneath the hopper with virtually no clearance. Each port of the powder wheel contains a piston, and a vacuum plate is positioned behind the wheel. Spring pressure ensures zero clearance between the powder wheel and the vacuum plate.
A precise volume of powder is drawn into each port under vacuum. Different fill sizes are achieved by adjusting the piston length. Excess powder is removed by a doctor blade, which can be adjusted externally without removing the powder hopper. As the powder wheel indexes further, the powder remains held in the port by vacuum until it reaches the position directly above the container. At this point, a timed pulse of sterilized low-pressure compressed air (or nitrogen) sequentially ejects the powder from the port into the waiting container. Immediately after filling, the containers are separated on the conveyor by a vial separator and proceed to the stoppering station.
Sterilized and siliconized rubber stoppers are stored in a vibratory bowl, from which they are oriented and stacked vertically in the rubber stopper chute. Each container is firmly held between a pair of timing belts so that it can pick up a rubber stopper from the exit end of the chute. The container then passes between two pressing rollers that securely seat the rubber stopper for a tight fit.
Models | APF 12S | APF 12D |
Production Output | Up to 100 vials/minute | Up to 200 vials/minute |
Fill Volume | 50 mg. to 10grams | 50 mg. to 10 grams |
Vial Size | 5ml to 250ml | 5ml to 250ml |
Filling Accuracy | ± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder | ± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder |
Power Load | 3.5 H. P. | 4.5 H. P. |
Overall Dimension | 2600mm (L) X 1100mm (W) X 1800mm (H) approx. | 3000mm (L) X 1100mm (W) X 1800mm (H) approx. |
Net Weight | 500 kgs. approx. | 700 kgs. approx. |
Gross Weight | 750 kgs. approx. | 950 kgs. 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.
Sterilized powder is agitated in the hopper to maintain uniform density. A vacuum-driven powder wheel with twelve ports draws a precise volume of powder into each port. Excess powder is removed by a doctor blade. When the port reaches the vial, a pulse of sterilized low-pressure air or nitrogen ejects the powder into the container. Filled vials then move to the integrated rubber stoppering station.
The machine typically achieves a filling accuracy of ±2% to ±3% in single dosing, depending on the consistency and bulk density of the injectable powder and controlled environmental conditions.
Depending on the model, output ranges from up to 100 vials per minute (APF 12S – single powder wheel) to up to 200 vials per minute (APF 12D – double powder wheel).
It can process vials from 5 ml to 250 ml and fill volumes from 50 mg to 10 grams. Multiple dosing is possible with the help of change parts.
Yes. All product-contact parts are made of SS316L stainless steel with an easy-removal system for cleaning, autoclaving, and sterilization. Optional inbuilt laminar airflow for Class 100 environments further supports aseptic processing.
Yes. It features a built-in rubber stoppering system. Sterilized siliconized rubber stoppers are automatically oriented in a vibratory bowl and securely inserted into the filled vials using timing belts and pressing rollers.
Key features include a clutch system for vial breakage protection, no-vial-no-fill sensors, tool-free adjustment of doctor and wiper blades, optional PLC with HMI, and optional sampling and automatic rejection systems.
Yes. IQ/OQ validation documentation can be supplied on request to support regulatory compliance and qualification activities.
Yes. It can be seamlessly connected with vial washing machines, sterilization tunnels, capping machines, labeling systems, and inspection equipment to form a complete sterile injectable powder filling line.
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Connect with our engineering team to discuss your specific production requirements. We provide customized, cGMP-compliant machinery solutions designed to optimize your manufacturing facility and maximize output.
Adinath International manufactures high-precision pharmaceutical packaging machinery and production plants, providing reliable, hygienic, and efficient solutions for global pharmaceutical industries.
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