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

High-Precision Monoblock Solutions for Sterile Pharmaceutical Injectables

In sterile pharmaceutical manufacturing, accuracy, contamination control, and equipment reliability are critical. The Automatic Injectable Vial Dry Powder Filling & Stoppering Machine (Single Wheel / Head) (Volumetric) from Harsiddh Unimach Pvt. Ltd. is engineered to meet these strict global standards. Designed as a compact, high-performance monoblock system, this machine integrates high-precision powder dosing and rubber stoppering into a single, cohesive framework.

By unifying filling and sealing operations, this machine minimizes vial transport distances, drastically lowering the risk of airborne contamination and environmental exposure. It is engineered for the precise dosing of sterile dry powders and antibiotics into glass vials, providing a dependable solution for modern injectable manufacturing lines.

Exceptional Technical Architecture & Core Dosing Mechanism

At the core of this machine lies a high-efficiency, single-wheel volumetric filling mechanism. Unlike traditional auger systems that can cause friction and break sensitive powder granules, our vacuum-suction powder wheel utilizes a gentle differential pressure method.

[Rotary Turn Table] ➔ [Slat Conveyor] ➔ [Volumetric Powder Wheel] ➔ [No-Vial-No-Fill Sensor] ➔ [Rubber Stoppering Station] ➔ [Out-feed Discharge]

1. The Vacuum-Pressure Dosing Sequence

The single-wheel assembly features precision-machined cavities or ports calibrated to the target dose weight. As the wheel rotates through the powder hopper, a precisely timed vacuum suction draws a uniform density of powder into each port.

2. Doctor Blade Levelling

To ensure absolute volumetric uniformity, an adjustable doctor blade shears off any excess powder from the surface of the wheel ports. This ensures that every individual pocket contains an identical volume of product before it reaches the discharge point.

3. Sterile Air/Nitrogen Purge Ejection

Once a vial is positioned directly beneath the dosing port, the system switches from vacuum to a positive pressure pulse (using sterile compressed air or an inert nitrogen gas flush). This pulse cleanly discharges the entire contents of the port into the vial neck without leaving static residue behind.

Scalable Engineering Specifications

Designed for versatility across diverse batch sizes, the machine seamlessly processes standard glass vials and various rubber stopper formats.

• Vial Processing Range: Standard configurations effortlessly handle glass vials spanning from 5ml to 30ml in capacity. The transport track and starwheel parameters can be adjusted with minimal changeover parts to accommodate different container diameters and heights.
• Flexible Dosing Capabilities: The volumetric powder wheel accommodates single-dose weights ranging from 50mg to 1.5 grams. Attaining higher fills is easily achievable through modified wheel port dimensions or utilizing dual-dose operations, maintaining a strict filling accuracy within pharmaceutical compliance thresholds.
• Stoppering Specifications: The integrated stoppering module is designed to apply standard 20mm slotted or formulation rubber stoppers. This makes it fully compatible with both conventional injectables and lyophilized products requiring partial stopper insertion for subsequent freeze-drying processes.

Continuous Automated Operational Workflow

The system provides a continuous, automated workflow from raw container input to securely stoppered vials, requiring minimal operator intervention.

Step 1: Automated In-feed and Sorting

Empty, sterilized glass vials are loaded onto a heavy-duty, variable-speed rotary turn table. The rotary motion gently guides the containers onto a premium stainless steel (SS 304/316) slat conveyor track. A mechanical guiding arm aligns the vials into a single-file stream, smoothly accelerating them toward the processing zone.

Step 2: Volumetric Powder Charging

The synchronized indexing mechanism positions each vial directly underneath the active port of the rotating powder wheel. As detailed in the dosing mechanism, the vacuum-assisted pocket drops the precise micronized powder dose cleanly into the vial.

Step 3: Advanced “No Vial – No Fill” Verification

Integrated electronic sensors continually scan the conveyor line. If a gap in the vial stream is detected, the machine’s control system instantly bypasses the vacuum-suction and piston discharge cycle for that specific port. This prevents expensive powder from blowing into the empty conveyor track, eliminating product waste and keeping the mechanical environment pristine.

Step 4: Precision Vibratory Rubber Stoppering

Immediately after receiving its powder charge, the vial is conveyed to the rubber stoppering station. Stoppers are sorted and aligned via an overhead, low-noise vibratory bowl feeder. They travel down a polished feed chute to a pick-and-place matrix or vacuum arm. The machine precisely picks up each individual stopper and presses it firmly into the vial neck. The insertion depth is fully adjustable to ensure a hermetic seal or a partial seal suited for freeze-drying applications.

Step 5: Secure Discharge & Downstream Routing

The completely filled and stoppered vials are guided away from the processing core via the exit starwheel. They emerge onto the out-feed conveyor section, ready to be linked directly into downstream machinery, such as an automatic aluminum cap crimping/sealing machine, external vial washing equipment, or a visual inspection conveyor belt.

Designed for Cleanroom Integrity and cGMP Compliance

Harsiddh Unimach Pvt. Ltd. builds every machine with a deep commitment to current Good Manufacturing Practices (cGMP). The structural design is engineered to streamline validation processes and uphold cleanroom environment standards.

• Superior Metallurgy: All product contact components—including the powder hopper, dosing wheel, agitator blades, conveyor guides, and delivery chutes—are made from mirror-polished Stainless Steel 316L. This non-reactive, corrosion-resistant grade prevents cross-contamination and withstands aggressive sanitization procedures. Non-contact structural surfaces and external enclosures are built from durable Stainless Steel 304.
• Controlled Humidity Layout: Because dry powders are highly hygroscopic, even minor atmospheric moisture can cause clumping and affect filling weight accuracy. The compact design easily integrates inside a customized Laminar Air Flow (LAF) hood or an isolated glass enclosure system. This allows operators to maintain a strictly controlled, low-humidity micro-environment directly around the open powder hopper and filling zone.
• Tool-Less Changeovers & Easy Sanitization: The filling wheel, hopper parts, and transport guides are engineered for rapid disassembly without requiring specialized tools. This user-friendly layout dramatically reduces batch turnaround times, facilitates deep autoclaving of contact elements, and minimizes maintenance overhead.

Intelligent Control Architecture and Safety Measures

Operating this dry powder filling line is intuitive and safe, thanks to its modern electronic control system.

• Centralized Control Panel: The machine is operated through an ergonomic Human-Machine Interface (HMI) touchscreen coupled with a programmable logic controller (PLC). Operators can adjust filling speeds, monitor batch counts in real time, configure conveyor synchronization, and view detailed diagnostics from a single panel.
• Safety Clutches and Interlocks: To safeguard mechanical components from accidental damage, safety overload clutches are integrated into the main drive shafts and indexing wheels. If a vial jams or tipping occurs, the machine instantly brakes to prevent component breakage. Transparent acrylic safety interlocked doors surround the main workstation; opening any door automatically pauses operations.

Technical Specification

Specification	Details (HPF-120 Series)
Production Output	40 to 100 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% (Subject to Bulk Density & Humidity)
Rubber Stopper Size	20mm (Standard)
Contact Parts	Stainless Steel AISI 316L
Main Drive	Imported Gear Motor with VFD
Sterilization	All contact parts are Autoclavable

Why Choose Harsiddh Unimach Pvt. Ltd.?

Investing in our automatic single-wheel injectable dry powder filling and stoppering system gives pharmaceutical manufacturers a competitive edge through reliable engineering and precision. By removing complex mechanical linkages and focusing on a streamlined, single-wheel volumetric design, we deliver an industrial system that offers maximum uptime, minimal product loss, and repeatable accuracy.

Whether processing critical antibiotic powders, cephalosporins, or specialized sterile injectables, this machine provides the operational consistency your cleanroom requires. Empower your production facility with a high-speed packaging solution backed by the engineering excellence and comprehensive technical support of Harsiddh Unimach Pvt. Ltd.

Frequently Asked Questions