Automatic Vial Powder Filling Machine

Q: What is the production capacity and filling accuracy of the machine?

The machine is available in two models: APF 12S : Up to 100 vials per minute APF 12D : Up to 200 vials per minute It handles vial sizes from 5 ml to 250 ml and fill volumes from 50 mg to 10 grams . The standard volumetric filling accuracy is ±2–3% , depending on powder characteristics, density, and environmental conditions. Advanced servo-controlled options can achieve even higher precision. The “No Vial – No Filling” system prevents costly powder wastage.

Description

Injection powder vials can be filled using a Automatic Vial Powder Filling Machine, also known as a vial powder filler. Filling and stoppering/bunging operations are carried out on the same platform by the monoblock Sterile Powder Filler. In pharmaceutical plants with high production volumes, it is frequently used to package sterile powder injections of antibiotics. For cGMP compliance, all contact parts are constructed from FDA-approved materials or stainless steel 316L.

With a maximum speed of 200 vials per minute, the automatic vial powder filling machine is appropriate for round glass vials. It includes built-in turn tables at the infeed and outfeed with separate drives to match the speed of entering and outgoing vials. SS316 materials are specifically used to make parts that come into touch with powders. The Vial Filling Machine has a single head, single track, eight port powder wheel that uses vacuum and air systems to fill powder into glass vials. It also has an online vibrator-style rubber stoppering system that inserts stoppers continuously at a synchronised machine speed. Customised vial filling machines are available in a variety of variations to meet the needs of the user, including Single Track Double Powder Wheel, Double Track Double Powder Wheel, Single Track Single Powder Wheel, and Double Track Single Powder Wheel System.

Vial Preparation: Empty sterile glass vials enter via infeed turntable after upstream washing and depyrogenation (using hot air ovens or tunnels).

Powder Filling: Vials are positioned under the powder wheel. Vacuum/pressure draws and dispenses a precise powder dose into each vial. Agitators ensure consistent flow.

Stoppering: A vibrating feeder drops rubber stoppers, which are pressed into place.

Outfeed and Integration: Filled and stoppered vials exit to capping/sealing stations. The entire line can achieve up to 19,200 vials per hour in high-speed models.

Inspection: Inline checks for fill weight, stopper placement, and defects.

Salient Features of Automatic Vial Powder Filling Machine

Compact cGMP model.
“No Vial, No Filling” system eliminates wastage of costly powder.
Multiple Dosing System.
High Volumetric Filling Accuracy of ±2% of uniform density Injectable powder can be ensured by setting the depth of piston in the port of powder wheel.
Built-in Rubber Stoppering Unit saves lot of space in the Sterile Area & reduces the length of Laminar Flow.
Digital counter for counting production output.

Individual drive for the filling & sealing to match the speed of filling & sealing.
All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.
Safety clutch system to avoid Vial breakage.
Variable AC Frequency Drive for speed adjustment.
All contact parts are easily removable for mandatory Autoclaving/ Sterilization.

Working Principle of Automatic Vial Powder Filling Machine

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.

Technical Specification of Automatic Vial Powder Filling Machine

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.

Types of Vial Filling Machine

Automatic Vial Filling Machine

High Speed Vial Filling Machine

Vial Liquid Filling Machine

Vial Powder Filling Machine

Automatic Vial Filling and Rubber Stoppering Machine

Lab Scale Vial Filling Stoppering & Cap Sealing Machine

Injectable Vial Powder Filling & Stoppering Machine

Peristaltic Pump based Vial Filling Machine

Applications of Vial Powder Filling Machine

Benefits of Automatic Vial Powder Filling Machine

High Accuracy and Consistency

Increased Efficiency and Productivity

Reduced Labor Costs and Human Intervention

Minimized Product Waste and Spillage

Enhanced Hygiene, Safety, and Reduced Contamination Risk

Key Features of Automatic Vial Powder Filling Machine

Powder Dosing System: Utilizes vacuum-driven powder wheels or servo-controlled pistons for volumetric filling. Powder is stored in a hopper agitated by mechanical stirrers to maintain uniform density. Dosing ranges from 50mg to 1500mg per vial, with options for multiple doses via changeable parts.

Filling Accuracy: Typically ±2% (or better, up to ±0.05% in advanced servo models), depending on powder characteristics, humidity, and environmental conditions.

Stoppering Mechanism: Built-in rubber bunging or stoppering system inserts sterile stoppers immediately after filling to preserve integrity.

Turntables and Conveyor: Infeed and outfeed turntables with independent drives for smooth vial handling and speed control. Vials are transported via a synchronized conveyor or indexing system.

Safety and Controls: Includes clutch systems for vial breakage prevention, tool-less blade adjustments, PLC interfaces with graphical user interfaces (GUI), and optional in-process weight checking or rejection systems. Many models support IQ/OQ validation documentation.

Sterility Enhancements: Options for inbuilt laminar airflow (Class 100), autoclavable SS316 contact parts, and integration under isolators or RABS (Restricted Access Barrier Systems).

Customization: Servo motors for powder wheel rotation and vial transport; adaptable for different vial sizes . Advanced models allow split-filling of multiple powders in one vial with 100% check-weighing.

FAQ for Automatic Vial Powder Filling Machine

What is an Automatic Vial Powder Filling Machine?

An Automatic Vial Powder Filling Machine is a compact, monoblock sterile powder filler designed for high-speed filling and rubber stoppering of injectable powders (such as antibiotics) into glass vials under aseptic conditions. It integrates powder dosing, filling, and stoppering on a single platform, ensuring cGMP compliance with minimal human intervention. It is ideal for pharmaceutical manufacturers requiring precise, contamination-free packaging of sterile dry powder injections.

What is the production capacity and filling accuracy of the machine?

The machine is available in two models:

APF 12S: Up to 100 vials per minute
APF 12D: Up to 200 vials per minute

It handles vial sizes from 5 ml to 250 ml and fill volumes from 50 mg to 10 grams. The standard volumetric filling accuracy is ±2–3%, depending on powder characteristics, density, and environmental conditions. Advanced servo-controlled options can achieve even higher precision. The “No Vial – No Filling” system prevents costly powder wastage.

Which types of powders and vials can this machine handle?

This machine is primarily designed for sterile, free-flowing to slightly cohesive injectable powders used in antibiotics and other parenteral formulations. It works with round glass vials (5 ml to 250 ml). The powder wheel system with vacuum and compressed air (or nitrogen) ensures consistent dosing even with powders that require uniform density. Changeable parts allow flexibility for different dose ranges and vial sizes.

Does the machine comply with regulatory standards and support sterility?

Yes. All product contact parts are made from FDA-approved materials or SS 316L and are easily removable for autoclaving/sterilization. The machine is built as a compact cGMP model and supports integration with Class 100 laminar airflow, RABS, or isolators. It can be supplied with IQ/OQ validation documentation and meets requirements of FDA, EU-GMP, and WHO guidelines for aseptic processing of sterile powders.

What are the key features and optional accessories available?

Key features include:

“No Vial, No Filling” system
Built-in online rubber stoppering unit
Safety clutch to prevent vial breakage
Variable speed control via AC frequency drive
Individual drives for filling and stoppering
Digital production counter
Overload and jamming protection

Optional accessories include inbuilt laminar airflow, servo motors, in-process weight checking with rejection, multiple dosing systems, and split-filling for different powders. Contact parts can be customized as per specific requirements.

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