Automatic Peristaltic Based Ampoule Filling Machine
Advanced Sterile Liquid Dosing & Hermetic Sealing for High-Value Injectables
In sterile pharmaceutical manufacturing, preventing cross-contamination and achieving pinpoint dosing accuracy are critical benchmarks. The Automatic Peristaltic Based Ampoule Filling & Sealing Machine engineered by Harsiddh Unimach Pvt. Ltd. is an industry-leading solution built specifically to meet these demanding criteria. Designed for the high-speed processing of glass ampoules, this sophisticated system integrates gentle fluid handling with robust mechanical engineering to serve the world’s most sensitive biotechnology and pharmaceutical production lines.
By replacing traditional mechanical piston pumps with advanced digital peristaltic dosing systems, this equipment provides an completely isolated fluid path. It is the premier choice for contract manufacturers and pharmaceutical facilities handling high-cost biologics, oncology drugs, vaccines, and volatile fluids that demand strict sterile integrity and compliance with global regulatory standards.
The Peristaltic Advantage: Redefining Purity in Injectable Packaging
Traditional volumetric piston fillers depend on moving metallic or ceramic parts that rub against one another inside a cylinder. Over time, this friction can generate microscopic particulates, and cleaning the internal components requires extensive breakdown, increasing the risk of batch-to-batch cross-contamination.
The peristaltic technology utilized by Harsiddh Unimach Pvt. Ltd. completely reengineers this process:
- Zero Mechanical Product Contact: The liquid medication passes exclusively through medical-grade, platinum-cured silicone tubing and precision-engineered delivery nozzles. It never comes into contact with any moving mechanical pumps, valves, or seals.
- Rapid Clean-In-Place (CIP) & Validation: Product changeovers take only minutes rather than hours. Operators simply swap out or autoclave the flexible tubing assembly, drastically accelerating validation times and minimizing machine downtime.
- Gentle Fluid Dynamics: Peristaltic pumps rely on smooth, rotational roller pressure to draw and displace liquid. This low-shear pumping action is ideal for complex protein structures, live biological cultures, and viscous diagnostic reagents that degrade under high mechanical stress.
High-Precision Operational Architecture & Sequential Workflow
Our engineering incorporates a specialized Slant Travel Principle to handle glass ampoules of varying wall thicknesses and neck profiles with minimal friction. This ensures smooth transport, reducing glass-on-glass friction and preventing costly breakage on the production floor.
[Hopper Loading] ➔ [Nitrogen Pre-Gassing] ➔ [Peristaltic Dosing] ➔ [Gas Flushing & Sealing] ➔ [Sterile Tray Discharge]1. Synchronized Ampoule Infeed & Loading
Sterile, washed glass ampoules are introduced via a specialized slant hopper. An intelligent eccentric rack assembly working alongside a synchronized star-wheel mechanism picks up the fragile containers. This ensures that every single ampoule is spaced perfectly and advanced smoothly into the transport carrier without scratching or chipping.
2. Advanced Pre-Gassing (Oxygen Displacement)
To protect oxygen-sensitive formulations from degradation and oxidation, the system features an integrated nitrogen gas-flushing station. Before any liquid is introduced, an inert gas layer is injected deep into the neck of the ampoule, completely clearing out atmospheric oxygen and establishing a highly stable micro-environment.
3. Ultra-Accurate Peristaltic Liquid Discharging
As the ampoules pass under the filling head, the digital PLC-controlled peristaltic pumps activate. The fluid is accurately metered and dispensed with exceptional repeatability across a wide dosing spectrum (supporting single doses from 0.5ml up to 25ml). Proximity sensors govern the “No Ampoule, No Fill” security protocol, guaranteeing that fluid is never discharged if a station is empty.
4. Post-Gassing, Pre-Heating, and Hermetic Sealing
Following the liquid delivery, a secondary post-gassing cycle seals an inert nitrogen blanket over the product. The ampoules then advance to the sealing zone, where they rotate continuously to distribute heat evenly. A customized fuel mixture of LPG and Oxygen pre-heats thick glass before a precise flame melts the glass neck, drawing away the waste tip to form a perfectly rounded, hermetically sealed dome.
5. Automatic Collection and Discharge
The fully sealed, sterile ampoules are moved gently out of the active sealing station via a delivery rack. They are deposited smoothly into an integrated collection tray for onward transport to optical inspection stations, labeling, and secondary cartoning lines.
Key Technical Attributes & Engineering Features
- Premium Material Execution: All frame structures, covers, and conveyor components are fabricated from robust Stainless Steel 304. All fluid contact paths and specialized nozzles utilize superior Stainless Steel 316L and pharma-compliant polymers to guarantee absolute chemical inertness.
- Scalable Production Capacities: To support everything from laboratory R&D batches to massive commercial campaigns, this equipment can be configured with anywhere from 1 to 8 filling heads, achieving throughput speeds of up to 250 ampoules per minute.
- Intelligent PLC Control Panel: A centralized touchscreen Human-Machine Interface (HMI) allows operators to fine-tune individual pump speeds, changeover adjustments, gas delivery pressures, and timing intervals digitally without mechanical retooling.
- Flawless Burn-Off Collection: The integrated sealing system features an automatic waste disposal chute that collects discarded glass tips cleanly beneath the active deck, keeping the primary aseptic zone immaculate.
Ideal Applications in the Pharmaceutical and Biotechnical Sectors
The absolute sterility and high accuracy of the peristaltic architecture make this machine indispensable for high-stakes packaging applications:
- Biologics & Biopharmaceuticals: Ideal for packing highly sensitive peptide solutions, monoclonal antibodies, gene therapies, and fragile vaccine formulations.
- Small Volume Parenterals (SVP): Perfectly optimized for standard hospital injectables, including anesthetics, antibiotics, analgesics, and sterile saline concentrates.
- Cosmetic Serums & Nutriceuticals: Excellent for sealing premium anti-aging vitamins, liquid collagen treatments, skin boosters, and highly concentrated essential hair nutrients in glass ampoules.
- Diagnostic Reagents: Extensively used to fill exact doses of laboratory controls, chemical indicators, and active testing reagents that require contamination-free processing.
Technical Specification
| Model No. | HFS-30P to HFS-225P |
|---|---|
| No. of Heads | 1, 2, 4, 6, or 8 Heads |
| Ampoule Sizes | 1ml to 25ml (Open & Closed Mouth) |
| Output / Minute | 20 to 250 Ampoules (Depending on model) |
| Filling Type | Peristaltic Pumps with Servo/Stepper Motors |
| Filling Accuracy | +/- 0.5% to 1% |
| Power Requirements | 0.5/1 H.P., 220 Volts, 1 Phase, 50 Hz |
| Gases Required | LPG & Oxygen (for Sealing) |
| Contact Parts | Stainless Steel AISI 316L |
Why Choose Equipment from Harsiddh Unimach Pvt. Ltd.?
As a premier manufacturer of industrial packaging machinery, Harsiddh Unimach Pvt. Ltd. focuses on building lines that seamlessly combine mechanical strength with smart digital control. Our Automatic Peristaltic Based Ampoule Filling Machine eliminates the hidden risks of cross-contamination while giving your operators complete digital control over every milliliter of product.
Maximize your yield, streamline your validation protocols, and safeguard your sensitive liquid formulations with world-class automation. For customized line configurations, integration with Clean Room Laminar Air Flow (LAF) systems, or to request a comprehensive technical quotation, reach out to our global sales and engineering division.
- Official Product URL: https://www.harsiddhunimach.com/product/automatic-peristaltic-based-ampoule-filling-machine/
- Corporate Technical Support: info@harsiddhunimach.com
Frequently Asked Questions
How accurate is the filling volume with a Peristaltic Based system?
Harsiddh utilize high-precision stepper or servo-driven motors to control the pump rollers. This technology allows for extremely accurate micro-dosing, achieving a filling accuracy of ±0.5% to 1%. It is particularly effective for small volumes ranging from 0.5ml to 10ml, ensuring minimal wastage of expensive pharmaceutical formulations.
Does the Peristaltic Filling system reduce "Downtime" during batch changes?
Yes, significantly. Since the liquid is contained entirely within the tubing, a "Changeover" often involves simply replacing the disposable silicone tubing set. This eliminates the need for time-consuming Cleaning-In-Place (CIP) or Sterilization-In-Place (SIP) of complex pump assemblies, allowing you to switch between different products in a fraction of the time.
Can this machine handle oxygen-sensitive injectable products?
Absolutely. The machine is equipped with integrated Pre-Gassing and Post-Gassing units. These stations flush the ampoule with Nitrogen (or another inert gas) before and after the filling process to displace oxygen. This ensures the chemical stability and extended shelf life of sensitive medications before the final hermetic seal is made.
What are the key cGMP and construction standards for this model?
As a cGMP-compliant unit, the machine is built for the most rigorous sterile environments:
Materials: All non-contact parts are SS 304, and the machine frame is designed with smooth surfaces for easy sanitization.
No Ampoule – No Fill: Electronic sensors ensure the pump only activates when an ampoule is present, preventing spills.
Control System: Features a centralized PLC with a Touchscreen HMI, allowing for digital calibration of fill volumes and real-time monitoring of production speeds.
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