Automatic Crushable Ampoule Filling & Sealing Machine
Advanced Micro-Dosing & High-Precision Flame Sealing for Specialized Glass Tube Packaging
In specialized pharmaceutical, veterinary, and agrochemical manufacturing, packaging fragile, thin-walled glass containers requires extraordinary precision and gentle handling. The Automatic Crushable Ampoule Filling & Sealing Machine engineered by Harsiddh Unimach Pvt. Ltd. is an industry-leading, automated solution explicitly designed to process delicate glass containers. This comprehensive system seamlessly accommodates Onion Skin Tubes (OST), traditional glass tubes, biological indicators, and crushable ampoules.
Constructed to meet rigorous international regulatory standards, this machine combines highly precise liquid dosing with robust flame-sealing mechanisms. By integrating advanced automation with superior mechanical engineering, Harsiddh Unimach Pvt. Ltd. provides a high-efficiency platform that maximizes throughput while eliminating product waste and container breakage.
Versatile Engineering: Processing Specialized Glass Substrates
Unlike standard pharmaceutical ampoules, crushable ampoules and onion skin tubes feature thin, calibrated glass profiles engineered to break under controlled pressure. Handling these brittle containers requires a specialized transport and filling architecture to prevent fractures during high-speed operations.
The Harsiddh Unimach Pvt. Ltd. system excels across multiple specialized formats:
- Onion Skin Tube (OST) Packaging: Optimizes handling for ultra-thin glass layers, ensuring uniform movement without structural stress.
- Crushable Glass Tubes: Delivers precise vertical alignment under the filling heads, eliminating mechanical impact.
- Biological Indicators & Diagnostic Tubes: Provides an ultra-clean, contamination-free processing environment required for sensitive microbiological media and diagnostic reagents.
High-Precision Operational Workflow
The machine operates on a continuous, fully synchronized mechanical sequence that guarantees stable tube positioning, accurate liquid delivery, and hermetic sealing.
[Tube Infeed & Tray Loading] ➔ [Pre-Nitrogen Purging] ➔ [Precision Micro-Dosing] ➔ [Post-Nitrogen Purging] ➔ [Pre-Heating & LPG-Oxygen Sealing] ➔ [Divided Sloped Tray Discharge]1. Smooth Infeed and Auto-Positioning
Empty crushable ampoules or glass tubes are loaded onto a high-capacity infeed hopper. A synchronized transport system gently moves each individual tube onto an indexing rack. The machine minimizes the need for extensive change parts, allowing operators to transition between different tube diameters and heights with minimal downtime and mechanical adjustments.
2. Pre-Filling Inert Gas Flushing
To preserve the chemical integrity and extend the shelf life of oxidation-sensitive products, the machine features an integrated pre-nitrogen flushing station. Atmospheric oxygen is efficiently displaced from inside the glass tube immediately before the liquid product is introduced.
3. Dual-Option Precision Dosing (Volumetric or Peristaltic)
Depending on your specific product characteristics, viscosity, and sterility requirements, the machine can be configured with two advanced dosing principles:
- Volumetric Piston Pumps: Ideal for achieving extreme accuracy across consistent batch runs.
- Peristaltic Pump Filling: Highly recommended for biological indicators and sterile fluids, as the liquid only contacts the medical-grade tubing, completely eliminating the risk of cross-contamination and facilitating rapid cleanups. The dosing system supports an ultra-precise single-dose filling range from 0.1 ml to 10 ml, adapting easily to micro-dosing applications.
4. Post-Filling Nitrogen Purging
Immediately after the liquid is dispensed, a second nitrogen-flushing unit injects inert gas into the head space of the filled tube. This dual-flushing mechanism guarantees that residual oxygen levels remain at an absolute minimum before the container is permanently sealed.
5. Advanced Pre-Heating & Hermetic Flame Sealing
Because thick-walled or specialty glass tubes can crack under sudden, extreme thermal changes, our machine features an active pre-heating unit. This station gradually warms the glass neck, preparing it for the primary sealing station. Using a precisely regulated mixture of Oxygen and Liquid Petroleum Gas (LPG), high-intensity burners melt the glass uniformly, creating a flawless, hermetic, and leak-proof tip seal.
6. Categorized Sloped Tray Discharge
Once sealed, the finished tubes are moved to an integrated sloped delivery tray. This collection station features proper physical divisions, allowing operators to smoothly manage, inspect, and transition the filled and sealed crushable ampoules to downstream secondary packaging areas without scratching or impacting the glass.
Technical Specifications & Built-In Advantages
- Premium Material Construction: To ensure complete compliance with global regulatory standards, all product contact parts are meticulously fabricated from AISI 316L stainless steel. This premium grade offers superior resistance to chemical corrosion and degradation, while the external structures are built from durable AISI 304 stainless steel.
- Customized Single-Motor Drive: The system utilizes an engineered single-motor architecture. This master drive perfectly synchronizes all major unit movements—including indexing, filling strokes, gas flushing, and tube rotation—ensuring flawless mechanical timing and preventing synchronization errors.
- Scalable Output Capacity: Built to support diverse manufacturing demands, the system delivers reliable production speeds ranging from 10 to 100 glass tubes per minute, depending on the fluid’s viscosity, dosing volume, and specific container dimensions.
- CE Certified Security: Fully compliant with European CE safety regulations, the machine is equipped with localized safety shielding, emergency stop mechanisms, and precise pressure regulators for the LPG and Oxygen sealing lines.
Diverse Cross-Industry Applications
The flexibility and high-precision capabilities of this filling and sealing platform make it an invaluable asset across multiple demanding industrial sectors:
- Veterinary Medicine: Ideal for packaging single-dose sterile veterinary liquids, serums, and targeted animal health treatments.
- Agrochemicals & Insecticides: Safely doses and hermetically seals concentrated agro-insecticides, chemical markers, and specialized soil treatment fluids.
- Biological Indicators: Extensively utilized by medical and sterilization validation manufacturers to fill glass ampoules containing specialized bacterial spore strips or growth media.
- Specialty Industrial Chemicals: Perfect for handling unique chemical reagents, testing kit components, and industrial lubricants that require airless, long-term storage in glass.
Strategic Investment Benefits for Modern Production Lines
Partnering with Harsiddh Unimach Pvt. Ltd. for your specialized packaging needs provides measurable commercial and operational advantages:
- Minimized Container Rejection: The progressive pre-heating assembly and gentle indexing mechanisms drastically reduce glass thermal shock and mechanical breakage, saving high-value glass containers and ingredients.
- Rapid Batch Changeovers: The versatile design handles glass tubes up to 10ml with minimal modification to change parts, maximizing overall equipment effectiveness (OEE) and minimizing line downtime.
- Uncompromising Dosing Accuracy: Whether filling 0.1 ml or 10 ml, the high-precision dosing system prevents product overfills, maximizing yield from expensive active ingredients.
Technical Specification
| Model No. | HFS-30 OST / HFS-55 OST / HFS-4 OST (Suitable For Onion Skin Tubes / Crushable Ampoules / Biological Indicator) |
| No. Of Head | One / Two / Four Heads |
| Size Of Onion Skin Tubes / Crushable Ampoules / Biological Indicators | Dia. 6mm to 15mm Length – 55mm to 100mm Or as per customer size |
| Filling Capacity | From 0.5ml to 5ml in single dose |
| Filling Type | Peristaltic Pumps Type Filling |
| Filling accuracy | +1% |
| Contact Parts | Stainless Steel AISI 316L (For Filling Nozzles) |
| Filling Head | One / Two / Four |
| Sealing Nozzle | One / Two / Four |
| Output / Minute | 10 to 100 Tubes / Minute (Depend on models) |
| Require Gases For Sealing | LPG & Oxygen (Mixture) |
| Nitrogen Purging | Available (Pre & Post) |
| Pre Heating | Available |
| Power Require | 0.5/1 H.P., 220 Volts, 1 Phase, 50 Hz OR Customized |
| Over All Dimensions | Depend on model |
| Net Weight | Depend on model |
| Gross Weight (With Wooden Case) | Depend on model |
Partner with Harsiddh Unimach Pvt. Ltd.
At Harsiddh Unimach Pvt. Ltd., we design advanced industrial machinery that bridges mechanical reliability with state-of-the-art process control. Our Automatic Crushable Ampoule Filling & Sealing Machine offers the exact gentleness, flexibility, and throughput required to handle your most delicate packaging challenges.
Optimize your specialty production line, protect your product chemistry, and achieve exceptional processing standards. To request a detailed technical consultation, tailored layout designs, or a commercial quote for your facility, contact our application engineering team today.
- Official Website: www.harsiddhunimach.com
- Corporate Inquiries: info@harsiddhunimach.com
Frequently Asked Questions
How does the machine handle such fragile glass without breakage?
Since crushable ampoules are engineered with extremely thin glass walls, the Harsiddh machine uses a Synchronized Walking Beam or Rotary Transport System. This mechanism minimizes glass-to-metal contact and utilizes soft-touch grippers or "star-wheels" made of medical-grade engineering plastics. This ensures that the ampoules are moved through the filling and sealing stations with zero mechanical stress.
What filling technology is used for micro-volume liquid dosing?
To ensure the accuracy required for diagnostic reagents, the machine is equipped with a Micro-Filling System, typically utilizing Peristaltic Pumps or Valveless Ceramic Pistons. These systems provide a dosing accuracy of ±0.5% to 1%, which is essential for the consistency of the chemical reaction when the ampoule is eventually crushed by the end-user.
How is the "Tip Sealing" process managed to protect the contents?
The machine uses a precision Oxygen-LPG Flame Sealing system. After filling, the ampoule neck is pre-heated and then "tip-sealed" by a specialized burner. To protect heat-sensitive reagents or biological spores inside the ampoule, the machine is designed with a Heat-Sink Cooling System or nitrogen flushing to maintain a stable temperature at the base of the ampoule while the top is being melted shut.
What are the key construction and compliance features of the machine?
As a cGMP-compliant model, the Harsiddh Crushable Ampoule machine is built for cleanroom environments:
Material: All contact parts are made of SS 316L, while the main structure is SS 304 stainless steel.
Automation: Managed by a centralized PLC with a Touchscreen HMI, allowing for precise control over flame temperature, filling speed, and conveyor timing.
Safety: Features a "No Ampoule – No Fill" sensor to prevent liquid wastage and an integrated exhaust system to safely remove combustion gases from the sealing flame.
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