Automatic Two Head Onion Skin Tube Filling & Sealing Machine
Specialized Monoblock Packaging Systems for Biological Indicators and Crushable Glass Ampoules
In specialized pharmaceutical manufacturing, biomedical engineering, and veterinary sciences, handling delicate, thin-walled glassware requires an exceptional level of mechanical precision. The Automatic Two Head Onion Skin Tube Filling & Sealing Machine designed by Harsiddh Unimach Pvt. Ltd. is an industry-leading, high-precision solution engineered specifically for processing onion skin tubes and ultra-fragile glass ampoules.
Commonly deployed for the packaging of biological indicators, microbial spore strips, culture media, and specialized diagnostic reagents, this advanced machinery successfully bridges the gap between fragile material handling and high-speed automated output. By incorporating a robust monoblock architecture, the system guarantees sterile fluid delivery, precise thermal sealing, and completely fracture-free container handling throughout the entire production cycle.
Understanding Onion Skin Tubes & Biological Indicator Packaging
Onion skin tubes are micro-thin glass containers designed to be easily crushable or broken at the point of use, often inside a flexible plastic sleeve, to release an internal liquid medium or biological indicator. Because these glass tubes feature walls that are significantly thinner than standard pharmaceutical ampoules or vials, they cannot withstand the aggressive mechanical forces of standard industrial filling lines.
The engineering team at Harsiddh Unimach Pvt. Ltd. has addressed this vulnerability by developing a specialized, low-friction transport and handling mechanism. The machine minimizes physical shock, eliminates glass-to-metal impact points, and uses uniform thermal distribution to seal the tubes without causing stress fractures or micro-cracks in the delicate glass body.
Step-by-Step Sterile Operational Workflow
The entire filling and sealing process is completed within a compact, fully synchronized monoblock footprint. This ensures that the delicate glass tubes move through minimal travel distances, maintaining sterile integrity and maximizing operational efficiency.
[Bulk Tube Feeding] ➔ [Star-Wheel Indexing] ➔ [Inert Gas Purging] ➔ [Dual-Head Piston Dosing] ➔ [Pre-Heating & LPG Flame Sealing] ➔ [Fragile Tip Separation & Tray Discharge]1. Automated Star-Wheel Feeding and Orientation
Delicate glass tubes are loaded into an specialized feeding hopper or chute. A custom-machined, synchronized star-wheel indexing system gently captures each individual onion skin tube. This rotational transport system guides the fragile glassware through successive stations with absolute stability, preventing body-to-body collisions that lead to hairline fractures.
2. Advanced Nitrogen Flushing (Pre-Filling Purging)
For biological indicators and sensitive diagnostic media, removing ambient oxygen from the container is critical to ensuring product shelf-life and preventing chemical degradation. Before any liquid is introduced, specialized flushing nozzles descend into the tubes to purge the interior volume with filtered nitrogen or an inert gas mixture.
3. Simultaneous Dual-Head Volumetric Dosing
The machine utilizes a highly accurate, dual-head volumetric piston pump mechanism. Operating simultaneously, the twin heads deliver two identical doses at a high rate of speed, effectively doubling the operational throughput of standard single-head equipment. The machine effortlessly processes micro-volumes ranging from 0.5ml to 5ml, maintaining an exceptional dosing accuracy tolerance of ±1% or better. The diving nozzle profile prevents liquid splashing onto the upper neck area, which is vital for achieving an airtight seal later in the cycle.
4. Post-Filling Gassing and Multi-Stage Thermal Sealing
Following the liquid dosing stage, a secondary post-filling inert gas flush can be performed to completely blanket the liquid surface. The star wheel then moves the filled onion skin tubes into the specialized sealing zone. Here, the tubes undergo a multi-stage thermal processing sequence:
- Pre-Heating Station: The upper neck of the glass is gradually warmed to prevent thermal shock.
- Hermetic Fusion Sealing: Utilizing a precisely balanced Liquid Petroleum Gas (LPG) and Oxygen burner mixture, the machine applies localized heat while the glass tube is gently rotated. This forms a smooth, rounded, and completely airtight hermetic seal.
5. Clean Waste Extraction and Vertical Discharge
Once the flame fuses the glass shut, the separated glass waste or tip segment is automatically pulled away and collected inside an integrated Stainless Steel (SS) tip collector chute. The completely sealed, sterile onion skin tubes are then smoothly released from the indexing mechanism and collected into a vertical discharge tray, ready for downstream secondary inspection or outer packaging.
Key Technical Engineering Features
- High-Throughput Dual-Head Design: By doubling the filling and sealing components, the machine achieves highly efficient production rates ranging from 60 to 90 tubes per minute, optimizing floor space and labor costs.
- Premium Monoblock Structural Integrity: Designed with a vibration-free, heavy-duty frame clad entirely in Stainless Steel (SS 304). All product contact components—including the volumetric syringes, delivery tubes, and filling needles—are manufactured from premium-grade SS 316L to adhere to international GMP and CE regulations.
- Precise Temperature Control Controls: Gas flow meters and high-precision pressure regulators ensure a perfectly stable, repeatable flame profile, resulting in consistent sealing aesthetics and eliminating structural weaknesses in the glass.
- No Tube, No Fill Interlock Safety: Integrated optical sensors constantly verify the presence of a container at the dosing station. If a slot in the star wheel is empty, the corresponding filling nozzle is instantly deactivated, preventing fluid spillage, equipment contamination, and media loss.
- Cleanroom Compatibility: The compact design and clean lines allow the machine to easily integrate underneath standard Laminar Airflow (LAF) workbenches and inside sterile cleanroom environments.
Specialized Industry Applications
The highly customized nature of the onion skin tube filling and sealing assembly makes it indispensable for several advanced medical and scientific sectors:
- Sterilization Validation Products: Packaging bacterial spore suspensions (such as Geobacillus stearothermophilus or Bacillus atrophaeus) used to validate autoclaves, ethylene oxide (EO) chambers, and dry-heat sterilizers.
- Veterinary Medicine: Processing low-volume liquid vaccines, specialty serums, and micro-dosed treatments requiring airtight, tamper-evident glass containment.
- Chemical and Diagnostic Reagents: Filling sensitive chemical indicators, water-testing reagents, and custom laboratory compounds that must remain completely isolated from atmospheric air until the exact moment of activation.
Technical Specification
| Specification | Details (Model: HFS-4 OST) |
|---|---|
| Number of Heads | Two (Filling & Sealing) |
| Compatible Glassware | OST / Crushable Ampoules / Biological Indicators |
| Tube Size Range | Dia. 6mm to 15mm | Length 55mm to 100mm |
| Production Output | 60 to 90 Tubes / Minute |
| Filling Capacity | 0.5ml to 5ml (Single Dose) |
| Filling Accuracy | +/- 1% |
| Gases Required | LPG & Oxygen (for Sealing) |
| Power Requirements | 1 H.P., 3-Phase or 1-Phase Options |
Partner with Harsiddh Unimach Pvt. Ltd. for Precision Automation
At Harsiddh Unimach Pvt. Ltd., we understand that niche pharmaceutical products require niche engineering solutions. Our Automatic Two Head Onion Skin Tube Filling & Sealing Machine combines gentle mechanical handling with high-speed digital timing to give you a reliable, zero-breakage production line.
Maximize your yield, safeguard delicate biological indicators, and achieve uncompromising sealing perfection. To discuss your required fill volumes, custom gas line plumbing, or to get a technical quotation tailored to your manufacturing plant, reach out to our engineering consultants today.
- Official Product Page: www.harsiddhunimach.com
- Contact Email for Technical Inquiries: info@harsiddhunimach.com
Frequently Asked Questions
What is the production capacity of the Two Head Onion Skin Tube model?
The Two Head configuration is an ideal solution for pilot plants, specialized diagnostic labs, and small-batch production. Depending on the tube diameter and the viscosity of the liquid, this machine can achieve a consistent output of 30 to 50 tubes per minute (approximately 1,800 to 3,000 per hour). It provides a professional level of automation while remaining compact enough for smaller facilities.
How does the machine prevent breakage during the transport and filling process?
To protect the fragile glass, the Harsiddh Two Head machine utilizes a Synchronized Walking Beam Transport System. The tubes are cradled in custom-contoured grippers made of medical-grade engineering plastics. This horizontal transport mechanism ensures that the tubes move smoothly through the nitrogen flushing, filling, and sealing stations with virtually zero mechanical stress.
How is the sealing process managed for such thin glass?
The machine employs a high-precision Oxygen-LPG Flame Sealing system. Because onion skin glass has a very low thermal mass, it melts almost instantly. The machine's PLC interface allows for micro-adjustments of the flame intensity and exposure time. This ensures a perfect, hermetic "tip seal" or "dome seal" is created without overheating the sensitive chemical reagents inside or charring the glass.
What are the key cGMP and construction features of this machine?
Even in its two-head configuration, this machine is built to the highest cGMP industrial standards:
Material Integrity: All liquid contact parts are made of SS 316L, while the exterior frame is polished SS 304 stainless steel.
Dosing Accuracy: Equipped with two high-precision volumetric syringes or peristaltic pumps, providing a filling accuracy of ±1%.
Cleanroom Ready: The slim-line design is optimized for placement under a Laminar Air Flow (LAF) unit to maintain a sterile environment.
Safety: Includes a "No Tube – No Fill" sensor to prevent liquid wastage and an integrated safety shield to protect the operator from the sealing flames.
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