Automatic Injectable Vial Dry Powder Filling & Stoppering Machine (Servo Based)
High-Speed Digital Aseptic Filling
The Harsiddh Servo-Based Injectable Powder Filler is engineered for pharmaceutical plants demanding the highest levels of automation and repeatability. By utilizing servo technology instead of traditional mechanical gears, this machine provides smoother transitions, lower maintenance, and the ability to handle complex multi-dosing requirements. It is designed to process glass vials ranging from 5ml to 30ml at high production speeds while maintaining an aseptic environment.
Reliable Operational Workflow
The machine manages a high-speed, synchronized cycle from bottle in-feed to hermetic sealing.
Sequence of Operation:
- Vial In-feed: Vials move from a sterilization tunnel to a rotary turn table and are indexed onto the conveyor.
- Servo Indexing: The servo-controlled star plate positions the vials precisely under the double or single-head filling station.
- Precision Filling: Powder is drawn into the ports by vacuum, scraped by a doctor blade for volume accuracy, and discharged into the vial using a sterile air pulse.
- Stoppering: Filled vials travel to the vibratory unit where stoppers are picked and placed into the vial necks under a constant vacuum.
- Discharge: Successfully stoppered vials are discharged via the out-feed turn table for inspection and final capping.
Technical Specification
| Specification | Details (Servo Series) |
|---|---|
| Model Type | Servo-Driven (Single or Double Wheel) |
| Production Speed | Up to 120 / 240 Vials Per Minute |
| Filling Range | 50mg to 1.5g (Single Dose); Up to 5g (Multi-Dose) |
| Filling Accuracy | ± 1% to 2% (Subject to Density) |
| Vial Diameter | 22mm to 45mm |
| Vial Height | 35mm to 100mm |
| Control System | PLC with Touchscreen HMI |
| Contact Parts | Stainless Steel AISI 316L |
Frequently Asked Questions
How does the Servo Motor improve dosing accuracy for dry powders?
In this machine, the rotation of the Vacuum-Pressure Dosing Wheel is governed by a Servo Motor. This allows the operator to fine-tune the filling parameters directly from the HMI (Touchscreen) with micro-precision. The system achieves a dosing accuracy of ±1%, ensuring that even expensive antibiotic powders are filled with minimal wastage and high repeatability.
Does the Servo model simplify the "Changeover" process for different vial sizes?
Yes, significantly. Traditional machines require manual mechanical adjustments for different vial heights and diameters. With the Harsiddh Servo model, many of these parameters are stored as "Recipes" in the PLC. When switching between vial sizes (e.g., 2ml to 10ml), the operator selects the pre-saved program, and the machine automatically synchronizes the filling and stoppering timing, reducing downtime by up to 50%.
How is sterile integrity maintained during the filling and stoppering process?
As a cGMP-compliant unit, the machine is designed for the most rigorous aseptic environments:
Laminar Air Flow (LAF) Ready: The slim, linear design is optimized for installation under a Class 100 LAF unit.
Vacuum-Pressure Principle: Powder is sucked into the dosing wheel using a vacuum and discharged into the vial using sterilized compressed air or Nitrogen, ensuring no manual contact.
Integrated Stoppering: Vials are stoppered immediately after filling via a synchronized "Pick & Place" station to prevent environmental exposure.
What safety and monitoring features are included in this high-tech model?
The machine is equipped with advanced sensors and interlocks managed by the PLC system:
No Vial – No Fill / No Vial – No Stopper: Prevents powder loss and ensures every vial is correctly sealed.
Safety Cabinet: Features a full acrylic safety enclosure with sensors that stop the machine if a door is opened during operation.
Real-time Diagnostics: The HMI displays live production statistics, batch counts, and instant error notifications for rapid troubleshooting.
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