Automatic Injectable Vial Dry Powder Filling & Stoppering Machine (Double Wheel / Head)

High-Speed Precision for Sterile Injectables

In large-scale pharmaceutical manufacturing, achieving both relentless speed and absolute volumetric precision is a continuous challenge. The Harsiddh Automatic Double Wheel Injectable Dry Powder Filler & Stoppering Machine solves this by engineering high-speed throughput and strict aseptic controls into a single, compact cGMP-compliant platform. Designed specifically for pharmaceutical lines handling 5ml to 30ml (and expandable up to 100ml) glass vials, this advanced system doubles the output of conventional single-wheel designs without taking up valuable floor space in your cleanroom.

By utilizing an innovative vacuum-and-piston volumetric principal alongside integrated nitrogen flushing, the machine guarantees clinical dosing accuracy for expensive antibiotic and sterile powder formulations. Immediately following the filling process, an onboard rubber stoppering module hermetically seals each vial, dramatically reducing the length of your Laminar Air Flow (LAF) zones and optimizing your overall sterile footprint.

Key Benefits & Industrial Advantages

• Optimized Cleanroom Footprint: Combining double-wheel powder dosing and precise rubber bunging into a single integrated monoblock system drastically reduces machine length, cutting down on expensive Laminar Air Flow (LAF) infrastructure costs.
• Exceptional Dosing Accuracy: Operating on an advanced volumetric principal with adjustable piston depths inside the powder wheel ports, the system ensures a minimal filling accuracy tolerance of just $\pm 1\%$, protecting high-value formulations from product giveaway.
• Sterile Contamination Countermeasures: All contact parts—including the twin powder hoppers, mechanical agitators, doctor blades, and stopper delivery tracks—are fabricated from premium AISI Stainless Steel 316 (SS316). Every contact component is rapidly detachable and completely autoclavable.
• Intelligent Product-Saving Sensors: Standardized with an electronic “No Vial – No Filling” and “No Vial – No Stoppering” system, the machine prevents powder wastage and component jamming by completely bypassing empty conveyor pockets.
• Minimized Structural Vibration: Built on a heavy-duty Stainless Steel square pipe frame structure equipped with adjustable leveling screws, the machine absorbs mechanical resonance to allow continuous high-speed runs without shifting or causing vial breakages.
• Global cGMP & CE Compliance: Designed and constructed in complete alignment with strict international regulatory standards, ensuring seamless validation (IQ/OQ/DQ documentation support) for global markets.

Reliable Operational Workflow

The system features a continuous, fully automated mechanical loop that safely synchronizes vial transit, micro-dose powder dispensing, and rubber stopper application.

[Rotary In-Feed Table] ➔ [SS Flat Conveyor] ➔ [Dual-Hopper Vacuum Dosing] ➔ [Sensor Check] ➔ [20mm Rubber Stoppering] ➔ [Out-Feed Turn Table]

1. Automated In-Feed and Component Transit

The cycle initiates at the attached high-performance rotary turn table. Vials are systematically indexed and transferred onto a high-quality SS flat conveyor belt. To prevent costly downtime caused by downstream line pressures, a built-in safety clutch system is integrated into the conveyor drive, stopping vial movement immediately if a tipping risk or structural obstruction is detected.

2. Dual Volumetric Vacuum Filling

Sterile bulk powder is housed inside dual-chamber hoppers, where it is gently agitated by mechanical stirrers to retain a uniform bulk density and eliminate clumps. As the double wheels rotate, an internal vacuum system draws the exact dose of sterile powder into the designated wheel ports. Precision-machined doctor blades scrap away any excess powder overfill from the wheel’s face before the machine discharges the metered doses into the glass vials using specialized pneumatic pulses.

3. Real-Time Smart Monitoring

Before advancing to the sealing station, the vials pass under an array of synchronized proximity sensors. These sensors instantly monitor the line for potential vial jams or missing containers. If an empty pocket is detected, the machine’s control logic initiates a selective bypass command, ensuring that the filling and stoppering heads do not actuate during that specific mechanical pulse.

4. Precision Rubber Stoppering

Immediately after undergoing the double-fill process, the open vials move under the vibratory rubber stopper bowl feed system. The 20mm rubber bungs are oriented smoothly along an SS316 track and accurately positioned on top of the vial necks via a pneumatic pick-and-place pressing mechanism. The close physical proximity of the filling and stoppering stations minimizes the time your bulk powders are exposed to the environment, maintaining sterile standards.

5. Contamination-Free Discharge

Once hermetically sealed with the rubber stoppers, the stabilized vials are smoothly swept off the linear conveyor track and guided onto an out-feed rotary turn table. From here, the components are systematically collected or directly routed to a downstream automatic aluminum capping machine and final optical inspection lines.

Technical Specification

Specification	Details (HPF-240 Series)
Model Number	HPF-240 (Double Wheel & Hopper)
Production Output	80 to 240 Vials Per Minute
Vial Size Range	5ml to 30ml Glass Vials (Dia. 22mm to 38mm)
Filling Capacity	50mg to 1.5g (Single Dose); Up to 6g (Multi-Dose)
Filling Accuracy	± 1.0% (Subject to Bulk Density & Humidity)
Main Drive	3 H.P. High-Performance Motor with VFD
Contact Parts	Stainless Steel AISI 316L
Machine Dimensions	3650mm (L) X 1000mm (W) X 1700mm (H)

Why Choose Harsiddh Unimach Private Limited?

With over three decades of engineering expertise based in Ahmedabad, India, Harsiddh Unimach Private Limited stands as a globally recognized manufacturer and exporter of advanced pharmaceutical packaging equipment. Our ISO 9001:2015 certified production processes utilize premium imported gearboxes, heavy-duty electrical contactors, and robust overload relays to guarantee unparalleled equipment lifespan and zero operational breakdown risks.

Whether you are expanding an antibiotic injectables filling facility or upgrading an analytical R&D pilot plant, our custom-engineered machinery provides the precise automated execution your operations demand. We supply worldwide to markets across North America, Europe, the Middle East, Asia, and Latin America with comprehensive export-grade wooden packaging and responsive after-sales technical field support.

For official inquiries, layout planning documents, or custom change-part options for the Automatic Double Wheel Injectable Dry Powder Filling & Stoppering Machine, contact our global sales department at info@harsiddhunimach.com or submit an instant quote request via our official webpage.

Frequently Asked Questions