Automatic Six Head Ampoule Filling & Sealing Machine
High-Speed Injectable Processing for Modern Pharmaceuticals
In the sterile manufacturing of liquid injectables, speed, precision, and uncompromised hygiene are the cornerstones of production success. Harsiddh Unimach Pvt. Ltd. designs and manufactures the state-of-the-art Automatic Six Head Ampoule Filling & Sealing Machine, an industry-leading solution engineered to meet the stringent demands of high-capacity pharmaceutical processing lines.
Built specifically for the simultaneous filling and sealing of glass ampoules, this high-speed equipment combines robust mechanical engineering with advanced automation. By utilizing the highly reliable and proven Angle Travel Principle, the machine delivers a exceptionally versatile filling capacity ranging from 0.5ml to 10ml. This wide handling spectrum allows pharmaceutical manufacturers to process various open-mouth ampoule sizes on a single platform with minimal changeover components. Featuring a high-performance six-head configuration, the system dramatically optimizes production output, smoothly achieving processing speeds ranging from 80 to 150 ampoules per minute depending on the liquid characteristics and container dimensions.
Engineering Excellence: The Operational Workflow
The entire architecture of our Automatic Six Head Ampoule Filling & Sealing Machine is engineered around the safe handling of delicate glass containers. To eliminate container friction, hairline fractures, and costly downtime due to breakage, the system employs a synchronized, cam-mechanism transfer structure. This ensures that every glass ampoule moves through the critical stages of the production line under continuous mechanical control and total stability.
Step-by-Step Sequence of Operation:
- Precision Loading and Feeding: Sterile glass ampoules are manually or systematically loaded into a heavy-duty slant hopper. From the hopper, a synchronized star wheel gently transfers the ampoules onto an eccentric rack, maintaining perfect alignment and uniform spacing.
- Pre-Gassing Decontamination: To safeguard the chemical stability of oxygen-sensitive pharmaceutical formulations, the ampoules undergo a rigorous pre-gassing phase. Pure Nitrogen gas is injected into the containers, effectively flushing out atmospheric oxygen and creating an inert environment before the liquid is introduced.
- High-Accuracy Volumetric Filling: Once stabilized, the ampoules align perfectly underneath the six-head filling station. Precision volumetric piston pumps discharge the exact liquid dose simultaneously across all six containers. The positive displacement mechanism guarantees exceptional dosing accuracy, minimizing product giveaway of expensive injectable formulations.
- Post-Gassing and Pre-Heating: Immediately following the filling stage, post-gassing with Nitrogen is executed to displace any remaining ambient air in the neck area. For thicker glass specifications, an optional pre-heating station gradually raises the temperature of the glass neck, preventing thermal shock during the final sealing stage.
- Hermetic Fusion Sealing: The filled ampoules advance seamlessly into an ultra-smooth, continuous-rotation revolving unit. Here, a carefully calibrated mixture of Liquefied Petroleum Gas (LPG) and Oxygen creates a uniform, intense flame. The machine utilizes a draw-off sealing method, melting the glass neck evenly and pulling away the waste tip to form a flawless, hermetically sealed dome.
- Contamination-Free Collection: Once sealed, the finished ampoules are automatically guided into a vertical collection tray. This discharge process operates entirely without human intervention, maintaining a strict sterile chain and eliminating the risk of microbial contamination.
Advanced Technology Integration & Customizations
At Harsiddh Unimach Pvt. Ltd., we recognize that every pharmaceutical formulation demands specific handling parameters. To accommodate unique viscosity levels, sterile restrictions, and automation preferences, our Automatic Six Head Ampoule Filling & Sealing Machine can be integrated with advanced, customizable drive and dosing technologies:
- Centralized Digital Automation (PLC & HMI): Upgrade your line with a high-performance Programmable Logic Controller (PLC) paired with an intuitive touchscreen Human-Machine Interface (HMI). This allows operators to monitor real-time production speeds, adjust timing parameters, track batch counts, and manage diagnostics from a centralized, user-friendly digital dashboard.
- Servo-Driven Dosing Systems: For applications requiring ultra-precise dosing accuracy beyond standard mechanical tolerances, we offer servo-based filling systems. Servo motors provide independent control over pump strokes, allowing for rapid, digital volume adjustments via the HMI screen and ensuring pristine consistency across long production runs.
- Peristaltic Pump Integration: For highly sensitive, bio-pharmaceutical products, shear-sensitive fluids, or high-value low-dose formulations, the machine can be configured with advanced peristaltic pumps. Because the fluid only contacts the medical-grade silicone tubing, this system offers rapid changeovers, eliminates cross-contamination risks, and simplifies the Cleaning-in-Place (CIP) or Sterilization-in-Place (SIP) validation protocols.
Technical Features & Performance Specifications
Investing in industrial machinery from Harsiddh Unimach Pvt. Ltd. means equipping your facility with highly durable, compliant, and reliable machinery. Below are the key engineering specifications designed into our six-head ampoule processing system:
| Feature / Attribute | Specifications & Capabilities |
|---|---|
| Output Rate | 80 to 150 Ampoules per Minute (Based on size & liquid viscosity) |
| Filling Range Capacity | 0.5 ml to 10 ml (With appropriate syringe/piston sizes) |
| Number of Heads | 6 Filling Heads & 6 Sealing Heads operating in parallel |
| Gas Requirements | LPG + Oxygen for Sealing; Nitrogen for Flushing/Gassing |
| Material of Construction | Stainless Steel 316L for fluid contact parts; SS 304 for structural frame |
| Container Compatibility | Standard Open-Mouth Glass Ampoules |
Key Advantages for Your Production Line
Choosing our six-head automatic processing line brings immediate operational efficiency and long-term compliance advantages to your facility:
- cGMP Compliant Architecture: The entire machine structure is manufactured using high-grade Stainless Steel. The clean, crevice-free design allows for seamless washdowns, sterilizations, and strict adherence to current Good Manufacturing Practices (cGMP).
- Minimal Product Waste: The highly accurate volumetric filling design ensures that precise fills are executed every cycle, reducing the risk of over-filling or under-filling sensitive injectable batches.
- Reduced Ampoule Breakage: By replacing standard harsh mechanical impacts with a smooth, continuous-motion cam mechanism, the glass ampoules glide effortlessly through the conveyor system, keeping structural loss to an absolute minimum.
- Flexible Scalability: The versatile frame allows for swift adjustments across varying container heights and fill volumes, enabling your production facility to handle a diverse product catalog with minimal investment in separate machinery.
Technical Specification
| Model No. | HFS-6 (High Speed) |
|---|---|
| No. of Filling Heads | Six |
| Output / Minute | 80 to 150 Ampoules (Depending on size) |
| Ampoule Size Range | 1ml to 10ml Open Mouth |
| Filling Capacity | 0.5ml to 10ml (Single Dose) |
| Filling Type | Volumetric Piston Pump |
| Power Requirements | 1 H.P., 3-Phase or 1-Phase Options |
| Machine Dimensions | 1950mm (L) x 1200mm (W) x 1000mm (H) |
| Net Weight | Approx. 750 Kgs |
Partner with Harsiddh Unimach Pvt. Ltd.
As an established leader in industrial packaging technology, Harsiddh Unimach Pvt. Ltd. is dedicated to delivering engineering solutions that increase throughput while maintaining international quality benchmarks. Our Automatic Six Head Ampoule Filling & Sealing Machine is the ideal asset for pharmaceutical manufacturers looking to elevate their injectable processing standards.
To discover how this advanced machine can integrate into your existing sterile cleanroom environment, or to discuss specific customization options tailored to your liquid formulations, visit our product page at https://www.harsiddhunimach.com/product/automatic-six-head-ampoule-filling-sealing-machine/ or contact our technical sales team today for an expert consultation.
Frequently Asked Questions
How does the machine ensure consistent dosing across all six heads?
To maintain strict pharmaceutical accuracy, the machine is equipped with six high-precision SS 316L volumetric syringes. These are driven by a synchronized cam or servo mechanism to ensure a filling accuracy of ±1%. The "No Ampoule – No Fill" sensor system ensures that if a gap is detected in the transport line, the corresponding filling head will not dispense liquid, preventing waste and contamination of the conveyor.
Can the machine process different ampoule types and sizes?
Yes. The Harsiddh Six Head machine is designed for versatility. It can handle open-mouth glass ampoules (Type B & C) ranging from 1ml to 25ml. The "Walking Beam" transport system features adjustable centering grippers, and the changeover parts—such as star-wheels and racks—can be swapped efficiently to accommodate different ampoule diameters and heights.
What sealing technology is used to ensure a hermetic closure?
The machine utilizes the "Draw-off Sealing" method, which is the gold standard for glass ampoules. After the filling and nitrogen gassing stages, the ampoule necks are heated by precision Oxygen-LPG burners. Once the glass reaches its melting point, mechanical grippers pull away the waste glass tip, creating a smooth, rounded, and perfectly hermetic "dome" seal.
What are the key cGMP and safety features of this Six Head model?
As a cGMP-compliant unit, this machine is built to the highest pharmaceutical standards:
Material Integrity: All liquid contact parts are SS 316L, while the exterior and non-contact parts are SS 304 stainless steel.
Nitrogen Flushing: Includes both pre- and post-filling nitrogen gas flushing stations to displace oxygen and ensure the stability of sensitive injectable drugs.
Operator Safety: The machine is housed within a transparent acrylic safety cabinet with interlock sensors that automatically stop the machine if the doors are opened during operation.
Control System: A centralized PLC with a Touchscreen HMI allows for easy monitoring of production speed, flame intensity, and batch counts.
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