Injectable powder vials are filled and rubber-stoppered using the Vial Powder Filling & Stoppering Machine (vial filler). Adinath provides a variety of vial filling machine models that are appropriate for the pharmaceutical sector. Our vial filling machines are simple to use and adhere to cGMP regulations. This machine can tolerate extended working hours and has a very robust build. A vacuum and air pressure-based powder wheel with a manual fill weight adjustment is used for filling.
The dry powder is first loaded into the upper filling hopper to start the filling operation. The precise pouring of the powder into the vials via a dosing disc is guaranteed by our machine’s clever design. This exact dosing system ensures uniform and consistent filling, reducing waste and increasing output. The vials are smoothly transferred for the stoppering process once they have been filled with the required quantity of powder. The seamless transition of our machine from filling to stoppering guarantees a smooth workflow and removes any production process interruptions. In particular, the machine frame structure and entire machine construction are finished in stainless steel. For more efficient operation, the machine has built-in Turn Tables at the In-feed and Out-feed with separate motors to match the speed of entering and outgoing vials. Every component that comes into contact with powders is composed of Ss316 materials. The machine has a single head, single track, eight port powder wheel that fills vials with powder using vacuum and air systems. It also has an online vibrator-style rubber stoppering system that inserts stoppers continuously at the machine’s synchronised pace.
Single and double powder wheel varieties of injectable powder filler are available, with manufacturing output ranging from 60 to 200 VPM. Servo-driven powder fillers allow for precise powder wheel placement. A specially designed vacuum-driven powder wheel that improves filling precision. Additionally, we provide vial labelling machines and vial cap sealing machines that create a fully automated vial powder filling line. To meet the unique needs of each customer, machines are also available in a variety of variations, such as Single Track Double Powder Wheel, Double Track Double Powder Wheel, Single Track Single Powder Wheel, and Double Track Single Powder Wheel System.
The sterilized powder is stored in powder hopper is agitated by pair of mechanical agitators for maintaining consistency and uniform bulk density. The powder wheel having eight ports rotates at the pre determined speed below the powder hopper with practically no clearance. Powder wheel consist of Piston in each port and behind the powder wheel vacuum plate is provided there is no clearance between powder wheel and vacuum plate due to back spring pressure. Precise volume of powder is sucked in to the port of powder wheel during vacuum according to the piston length different fill size can be achieved. The excess powder is doctored off by a doctor blade. Doctor blades can be adjusted from outside also without removing powder hopper. When powder wheel indexes further and remain in the port due to the vacuum till it reaches just vertically above the container. The time dose of Compressed air (Nitrogen Gas), sterilized low pressure air sequentially flushes out powder from the port of powder wheel in to the container one by one. The filled containers are immediately separated on the conveyor by vial separator and moves further for stoppering operation. (Different grooves separator can be used which depends on the container diameter or multiple dosing systems). The sterilized, siliconised, rubber stoppers stored in the vibrator bowl moves to vibratory bowl and stacked vertically in the rubber stopper chute. The container is hold firmly between pair or timing belt to pickup rubber stopper from exit end of the chute. Further the container is passed between two pressing roller for tight fit fixing of rubber stopper.
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.
The machine offers a filling accuracy of ±2% to ±3% (depending on powder bulk density and uniformity). Accuracy is achieved by adjusting the piston depth in the powder wheel ports along with consistent vacuum suction and compressed air/nitrogen flushing.
Sterile powder from an agitated hopper is drawn into the eight-port powder wheel by vacuum. Excess powder is removed by a doctor blade for uniform density. Compressed air (or nitrogen) then flushes the precise dose into the vial. Filled vials immediately move to the built-in vibrator-type rubber stoppering station for secure stopper placement, maintaining sterility throughout the process.
The machine can be customized with servo-driven systems, single/double powder wheel configurations, PLC with HMI, inbuilt laminar airflow, in-process weight checking, nitrogen flushing, and different change parts. It can also be integrated into a complete line with vial washing, depyrogenation tunnel, and capping machines. IQ/OQ documentation is provided for validation.
Key features include the “No Vial – No Filling” system, precise doctor blade control, safety clutch to prevent vial breakage, mechanical agitators for uniform powder density, and multiple dosing options. These features significantly reduce expensive sterile powder wastage and spillage.
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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 vial powder filling machines and complete packaging lines, providing reliable, hygienic, and efficient solutions for global pharmaceutical industries.
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