What is Vial Powder Filling Machine
Vial Powder Filling Machine or vial powder filler is filling device for filling injection powder vials. Sterile Powder Filler is the monoblock equipment perform filling and stoppering/bunging operations on same platform.
Systems range from manual tabletop to fully automatic
Our system is built in such a way that it works well in any condition. Regardless of the presence of a power source, the machines are able to operate manually and automatically.
Custom-built
Our Powder Filling Machine can be custom-built according to your needs and budget. We understand that needs vary and therefore we do this to meet every customer's requirements.
Robust construction
Our machines are built with high-quality materials to ensure they do not rust easily. We understand that the machine will be used to handle different powder.
Designed for product versatility
Our Powder Filling Machine are built to work just as efficiently. Our machines will be able to get the job done.
Minimal downtime for maintenance & cleaning
Our equipment is built to stand the test of time and therefore requires little time for maintenance and cleaning. Additionally, maintenance is not required frequently.
Easy setup with quick changeover features
Our Powder Filling Machine are user-friendly. Setting up the machine is easy and fast.switching to different features to fit a specific need is effortless.
Prefilled Syringe Filling Sealing Line
Aseptic prefilled syringe filling and sealing line is mainly used for the unpacking, tearing, filling, and plugging of disposable syringes in honeycomb trays in pharmaceutical plants. It is available for all kinds of bagged/nested boxes plastic/glass pre-filled syringes.
Glass Bottle Iv Filling Machine
In the glass bottle IV Infusion filling machine, bottles pass through the transfer track and the bottle feeding auger, and then enter into the filling station for filling with fixed spacing.
Plastic Bottle Iv Filling Machine
At present, there are mainly two types of bottle blowing machine of plastic bottle iv filling machine in the market, linear and rotary. Both of them all adopt a two-step method. The process is: bottle preform injection→ cooling and then heating the preform → stretching the bottle preform in the bottle blowing mold → blowing the bottle preform by high-pressure air to form bottles.
The soft bag IV filling machine is mainly composed of automatic film feeding mechanism, weak welding mechanism I, weak welding mechanism II, ink jet printer, forming station, primary port welding mechanism.
The syrup filling machine is an all-in-one machine for filling and capping glass syrup bottles, glass infusion bottles or similar bottles.
The vial filling machine is a new product developed by our factory to adapt to the development of world's biological and blood product engineering. This machine has advanced control system, accurate filling, stable performance and beautiful appearance.
This machine is an ampoule filling and sealing machine, not only keeping the function and features of common ampoule filling and sealing machines, but also improves its overall general performance: only a few parts are required for replacement for filling 1-5ml ampoule.
Pharmaceutical equipment belongs to a comprehensive application discipline involving pharmacy, especially pharmaceutical processing technology, biotechnology, chemistry, metal material science, mechanical principle, electrical engineering, refrigeration technology, HVAC technology, hydraulic and pneumatic technology, computer, etc.
Injection Vial Powder Filling Line
The vial powder filling machine can perform filling, stoppering and screw capping (capping) on glass bottles and plastic bottles. It adopts a closed high-precision cam-position device imported from Japan, with high precision, reliable operation and long service life.
Why Choose Us
Competitive pricing
We offer competitive pricing for our services without compromising on quality. Our prices are transparent, and we do not believe in hidden charges or fees.
Quality assurance
We have a rigorous quality assurance process in place to ensure that all our services meet the highest standards of quality. Our team of quality analysts checks each project thoroughly before it is delivered to the client.
Expertise and experience
Our team of experts have years of experience in delivering high quality services to our clients. We hire only the best professionals who have a proven track record of delivering exceptional results.
State-of-the-art technology
We use the latest technology and tools to deliver high quality services. Our team is well-versed in the and advancements in technology and uses them to provide the best results.
One-stop service
We promise to provide you with the fastest reply, the best price, the best quality, and the most complete after-sales service.
Customer satisfaction
We are committed to delivering high quality services that exceed our clients' expectations. We strive to ensure that our clients are satisfied with our services and work closely with them to ensure their needs are met.
Types of Powder Filling Machine Solutions
Vertical Form, Fill, Seal Machines (VFFS)
These machines perform three functions:
Forming of packaging bags/pouches from flat plastic film rolls
Filling the packages with the powder product
Sealing the filled packages with aluminum can sealer machines
Capsule Filling Machines
These are commonly used for filling pharmaceutical products and can only perform small powder fill amounts at once. They do not have scalable options too so they are among the less used fillers in the market.
Single Head Powder Filling Machines
Single head powder fillers can perform all of the filling processes using a single machine filling head. They can precisely fill both free-flowing and non-free flowing powder products. Though they only use a single filling head, they can produce accurate fills at fast speeds with smooth changeover of parts. they fill bulky powder products slowly.
Double Head Powder Filling Machines
These machines use two filling heads capable of handling bulky powders, unlike single head powder fillers. They can fill any powder product at fast filling rates and can handle several containers per minute. However, they are slower compared to net weight and auger fillers. double head powder fillers may sometimes produce inconsistent and inaccurate fill weights.
Auger Powder Filling Machines
Auger powder fillers are the most popularly used types of volumetric powder fillers and consist of an auger, stirring bar, and hopper. These are best suited for filling fine powders such as talcum powder, cake mixes, and flours at extremely fast speeds. They do not emit a lot of dust but they can be equipped with dust collectors whatever you prefer. Lastly, auger powder filling machines can fill both free-flowing and non-free-flowing powder products with uniform particles.
Vacuum Powder Filling Machines
Vacuum powder fillers can fill powder products into various containers without an agitator and auger. Meaning, the powders do not undergo any agglomeration or breakdown which preserves the product' s integrity.
They produce little to no dust and can handle both free-flowing and non-free flowing powders with fast changeover of parts.these machines are not recommended for handling powder granules requiring some breakdown.
Volumetric Cup Powder Filling Machines
These filling machines are ideal for handling free-flowing powder products but do not work well with non-free flowing powders. They can fill up to a hundred containers per minute and are quite more affordable than other filling machines. With their compressed structure, they can minimize mechanical damage.
Net Weight Powder Filling Machines
Net weight powder fillers are the only machines that weigh the powder product before filling it into the containers. They use weigh cells and check weighers to produce accurate fill weights. They can handle heavy granular and powder products and can even make up for inconsistencies in granules that are irregularly shaped.
Technical Specification of 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 10 grams |
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. |
Factors to Consider When Choosing Powder Filling
The high value of a powder product means that you need to put accuracy as one of your priorities. Filling accuracy is a tricky factor because even environmental factors affect the density of the product.
Quality issues fall victim whenever there are temperature fluctuations and humidity level changes. So, to avoid all this, it is best to go for a powder filling machine that can easily adapt when the production environment fluctuates.
That is why we advise on going for automatic machines that can overcome all these challenges. Apart from filling accuracy, our loss in weight feeder has the function of automating feeding, weighing, and batching.
With the twin screw loss weight feeder machine, you will adjust the mixing speed and frequency with ease. Which means it will improve the feeding accuracy and stability of the product.you will not only reduce labor costs, but also improve your workshop environment.
Most people ignore this factor, but it can save your business if considered. When it comes to accessibility, we are talking about how your operators and maintenance people can access various components of the machine as needed.
High-quality products, including powder filling machines, become better if support is provided. The support, in this case, goes back to the manufacturer. At times, machines can come in faulty, or some parts become affected after some time. In this case, you can always seek support from the manufacturer.
A powder filling machine is an example of automation in the packaging segment across industries. They are used to fill powder in a container using pieces of machinery. One of the main advantages of using powder filling machines instead of relying on human labor is in terms of performance precision. These machines can fill a container with required powder in precise volumes without getting impacted by the number of times the step is repeated.
They typically use a check weigher or weigh cell for measuring the quantity of powder in a container.powder filling machines can handle a wide range of powders across weights and sizes. The market for powder filling machines has grown over the years mainly due to the ease of packaging these devices provide along with being extremely easy to clean or maintain. For commercial purposes, there are multiple types of machines that are available in the market with each product offering specific characteristics.
Top 5 Industries that Benefits From Automatic Powder Filling Machine
There are several types of pharmaceutical filling machines available in the market, each designed for specific applications and production requirements. The most common types of filling machines include:
Pharmaceuticals Industry
The pharmaceutical industry requires precise and hygienic powder filling processes for medications, capsules, and powdered formulations. Automatic powder filling machines ensure accurate fill levels, minimize contamination risks, and enhance productivity. These machines can handle a wide range of pharmaceutical powders, including APIs (Active Pharmaceutical Ingredients) and excipients, meeting the stringent quality and regulatory requirements of the industry.
Food Processing Industry
Automatic powder filling machines are widely used in the food processing industry for filling powdered ingredients such as spices, seasonings, flour, baking mixes, powdered beverages, and dietary supplements. These machines ensure consistent and accurate fill levels, reduce product wastage, improve efficiency, and maintain hygiene standards. They are essential for achieving productivity in food manufacturing and packaging processes.
Chemical Manufacturing Industry
In the chemical industry, automatic powder filling machines play a crucial role in filling various powdered substances such as dyes, pigments, additives, detergents, and specialty chemicals. These machines provide precise filling volumes, ensuring batch consistency and eliminating human errors. They enhance efficiency, minimize cross-contamination risks, and ensure the safety of operators working with potentially hazardous chemicals.
Cosmetics and Personal Care Manufacturing Industry
The cosmetics and personal care industry benefits from automatic powder filling machines for filling powdered products like face powders, eyeshadows, blushes, talcum powders, and bath salts. These machines enable accurate and uniform filling, maintaining the desired texture and appearance of the products. They enhance production efficiency, reduce manual labor, and contribute to maintaining product quality and hygiene standards.
Agricultural and Horticultural Products
Automatic powder filling machines are utilized in the agricultural and horticultural sectors for filling powdered fertilizers, pesticides, insecticides, and plant growth supplements. These machines ensure precise dosing, reduce product wastage, and provide a consistent application of powdered products. By automating the filling process, they improve productivity, reduce human error, and ensure proper distribution of agricultural and horticultural substances.
Step-by-Step Guide to Using a Powder Filling Machine
Ensuring Your Machine is Properly Calibrated
Calibration is the basic step that makes sure your powder filling machine performs well. First, ensure the machine's settings are properly adjusted to match the properties of the product and the desired fill volume or weight. Calibration becomes a regular necessity as a result of the components of the machine undergoing natural wear and tear that may lead to inaccuracy. This could be done by using the standard weights to test the accuracy of the scale or by running diagnostic programs that are aimed at assuring the dispensing mechanisms are functioning well.
Loading the Powder into the Machine
Carefully load the powder into the machine, making sure to avoid contamination or spillage. Make the powder by checking for and removing the lumps and ensuring that it has a proper density, which is essential for even distribution. The hopper should be checked to make sure it allows the powder to flow smoothly and continuously into the filling machine. The use of sieves and vibration techniques ensures that the flow of powder remains uniform, which is a vital factor for even fills.
Setting Up the Fill Parameters
Setup the fill parameters by entering the exact amount of powder to be filled in each container. It is imperative to have a high level of accuracy in order to maintain the uniformity of the product. Set the machinery according to the product specs and container dimensions. Test these settings with a couple of trial runs to make sure that the machine gives the right amount every time, fixing any errors that might be present.
Running a Test Fill
Make sure to start with the series of test fills before moving to full-scale production. By doing so, this procedure detects any deviations or problems with the set parameters of the fill or the overall machine settings that may affect product quality. Evaluate the test results and apply any appropriate adjustments to ensure that the machine is ready for operation without producing any waste.
Adjustments and Troubleshooting
After filling the machine with the data, it is wise to check the settings and readjust them based on the results. It might be a case of adjusting the fill volume, altering the dispensing speed and pressing settings that will result to finer accuracy. Troubleshoot the problems during prototyping and then move on to the full production scale by resolving any problems that might arise.
Commencing Full Production
After all the adjustments have been made and all the machinery works smoothly, you can go on to production. Regularly check the machine behaviors to ensure the parameters are being maintained periodically and uniformly over a long time. Set up a plan of periodic inspections and maintenance for the machine to operate well at a long time, and thus the production quality is consistent.
Working Principle of 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 twelve ports which rotates at 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 into 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.
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 container is passed between two pressing roller for tight fit fixing of rubber stoppers.
Our Factory
Shanghai Marya Pharmaceutical Engineering and Project Co., Ltd. was founded in 2014 in Shanghai, China, is a total solution provider specializing in engineering design, clean room engineering, pharmaceutical engineering, pharmaceutical equipment, project management and verification and other technical services. We have three factories and a number of experts and technicians who have been engaged in pharmaceutical and medical industries for more than 20 years. Worriless and relieved solution for customer is our value proposition, we are consistently committed to helping clients to design and build clean workshops, pharmaceutical turnkey solutions.
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