Automatic Injectable Vial Dry Powder Filling & Stoppering Machine (Servo Based)
High-Speed Digital Aseptic Filling Technology
In modern sterile pharmaceutical manufacturing, precision, contamination control, and operational repeatability are non-negotiable. Harsiddh Unimach Pvt. Ltd. proudly introduces its state-of-the-art Servo-Based Injectable Vial Dry Powder Filling & Stoppering Machine. This next-generation system is custom-engineered for high-output pharmaceutical plants requiring advanced automation, absolute filling accuracy, and rigid compliance with global regulatory standards.
By replacing traditional, wear-prone mechanical gears and cam-driven mechanisms with cutting-edge multi-axis servo technology, this machine delivers incomparably smoother transitions, reduced mechanical friction, and significantly lower maintenance downtime. The integration of digital servo drives allows for real-time adjustments and provides the unparalleled flexibility required to handle complex multi-dosing formulations without compromising on speed or sterile integrity.
Designed specifically to process glass vials ranging from 5ml to 30ml, this high-speed aseptic filling line optimizes throughput while maintaining a flawless sterile environment. Whether you are processing antibiotics, biological products, or sensitive lyophilized powders, our system ensures that every vial is filled under optimal aseptic conditions, safeguarding product efficacy and patient safety.
Technical Specifications & Features
To compete on a global scale, pharmaceutical manufacturers require machinery that combines robust physical engineering with intelligent digital control. This servo-driven powder filler is built around a heavy-duty, GMP-compliant stainless steel frame, minimizing vibrations and eliminating the risk of particulate generation.
Key Engineering Highlights:
- Advanced Servo Automation: The elimination of traditional mechanical friction points reduces component wear and tear, resulting in significantly lower total cost of ownership (TCO) and minimal routine maintenance.
- Flexible Dosing Range: Capable of handling a wide array of fill weights across standard 5ml to 30ml glass vial profiles with swift, tool-less changeover parts.
- Aseptic Integrity: The machine structure is optimized to integrate seamlessly beneath Laminar Air Flow (LAF) units, maintaining strict Class A (ISO 5) environmental conditions across the filling and stoppering zones.
- Precision Vacuum-Pressure System: Utilizes an advanced pneumatic and vacuum distribution network to ensure reliable powder doctoring and zero-loss discharge.
- Intelligent Human-Machine Interface (HMI): Features a user-friendly touchscreen dashboard allowing operators to manage multi-dosing settings, track real-time production metrics, and log critical operational parameters.
Reliable Operational Workflow
The core strength of the Harsiddh Unimach design lies in its perfectly synchronized, automated cycle. Every movement—from raw vial entry to the final hermetic sealing stage—is electronically tracked and monitored to prevent cross-contamination, glass breakage, or product wastage.
Sequence of Operation:
1. Sterile Vial In-feed
The process begins immediately after the glass vials complete their sterilization and depyrogenation cycle. Moving seamlessly from the cooling zone of a sterilization tunnel, the sterile vials are transferred onto a heavy-duty rotary turn table. The turn table guides the containers onto a high-grip, low-friction conveyor belt line, organizing them into a single-file stream ready for indexing.
2. High-Precision Servo Indexing
As the vials advance down the line, a highly accurate, servo-controlled star wheel plate intercepts them. Unlike mechanical star plates that can cause jerky movements or micro-cracks in glass, our digital servo indexing system positions each vial under the dosing head with fluid, micro-millimeter precision. The system can be configured with either a single or double-head filling station, depending on your target production speeds and dosage profiles.
3. Vacuum-Assisted Precision Powder Filling
The dosing system operates on a proven vacuum-pressure principle to eliminate powder degradation. Sterilized powder is drawn into the ports of a rotating dosing wheel via a controlled vacuum. As the wheel turns, an adjustable doctor blade scrapes away any excess material, ensuring identical density and volume accuracy across every single dose. Once positioned directly over the vial neck, a precisely timed, sterile air pulse discharges the exact micro-dose of powder into the vial, completely eliminating airborne dust formation.
4. Automated Vacuum Stoppering
Immediately after receiving the powder dose, the filled vials travel directly to the integrated stoppering station. Rubber stoppers are fed continuously via a specialized electromagnetic vibratory bowl feed unit. The stoppers are picked and perfectly placed into the vial necks under a constant, controlled vacuum. This ensures that the stopper is seated firmly and accurately, creating an immediate barrier against moisture and atmospheric contamination before the vial leaves the sterile enclosure.
5. Continuous Out-feed & Discharge
Successfully filled and stoppered vials are transferred smoothly via the out-feed star plate onto the discharge turn table. From this point, the vials are safely routed forward for online visual inspection, rejection tracking (if integrated with check-weighing systems), and final aluminum 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 |
Why Choose Harsiddh Unimach Pvt. Ltd.?
As a trusted leader in industrial pharmaceutical machinery manufacturing based in Ahmedabad, India, Harsiddh Unimach Pvt. Ltd. understands the complex challenges of sterile powder handling. Powder filling demands meticulous attention to detail; static charges, humidity fluctuations, and powder density variances can completely derail production accuracy.
Our servo-based architecture directly addresses these issues by offering programmable parameters for different powder characteristics. When you partner with us, you are investing in:
- Uncompromising Compliance: All product-contact parts are manufactured from AISI Stainless Steel 316L, while non-contact structural components utilize AISI SS 304, fully satisfying cGMP, USFDA, and MHRA operational mandates.
- Customization Capabilities: We customize conveyor lengths, indexing speeds, dosing wheels, and vibratory bowl configurations to integrate flawlessly with your existing sterilization tunnels and capping equipment.
- Comprehensive Validation Support: We provide exhaustive documentation, including Installation Qualification (IQ), Operational Qualification (OQ), and detailed manuals to ensure seamless factory acceptance testing (FAT) and site commissioning.
Maximize Your Pharmaceutical Packaging Efficiency
Upgrading your sterile line with digital servo control means choosing higher efficiency, unmatched repeatability, and fewer batch rejections. The Automatic Injectable Vial Dry Powder Filling & Stoppering Machine (Servo Based) by Harsiddh Unimach Pvt. Ltd. is the ultimate solution for progressive pharmaceutical formulations.
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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