Injectable Dry Powder Filling with Rubber Stoppering Machine
Description :
Automatic Injectable Powder Filling with Rubber Stoppering is a compact model used for filling Stoppering of Dry Powder Injectable in to vials.
Operation :
The incoming dry container sterilized are fed through the Unscrambled and suitably guided on the moving delrin flat conveyor belt at the required speed of the correct placement below powder wheel. The sterilized powder is stored in powder hopper is agitated by pair of mechanical agitators for maintaining consistency and uniform bulk density. The powder wheel having eight ports rotates at the pre determined speed below the powder hopper with practically no clearance. Powder wheel consist of Piston in each port and behind the powder wheel vacuum plate is provided there is no clearance between powder wheel and vacuum plate due to back spring pressure. Precise volume of powder is sucked in to the port of powder wheel during vacuum according to the piston length different fill size can be achieved.
The excess powder is doctored off by a doctor blade. Doctor blades can be adjusted from outside also without removing powder hopper. When powder wheel indexes further and remain in the port due to the vacuum till it reaches just vertically above the container. The time dose of Compressed air (Nitrogen Gas), sterilized low pressure air sequentially flushes out powder from the port of powder wheel in to the container one by one. The filled containers are immediately separated on the conveyor by vial separator and moves further for Stop Pering operation. (Different grooves separator can be used which depends on the container diameter or multiple dosing systems). The sterilized, silicon zed, rubber stoppers stored in the vibrator bowl moves to vibratory bowl and stacked vertically in the rubber stopper chute. The container is hold firmly between pair or timing belt to pickup rubber stopper from exit end of the chute. Further the container is passed between two pressing roller for tight fit fixing of rubber stopper.
Technical Details :
| Model | SBPF-240 |
| Direction | Left To Right. |
| Production Rate | Up to 240 Fills / Min for Single Dose. |
| Fill Capacity | 50mg to 1.5gm Single Dose (with Change Parts) 1.5 gms to 6 gms. Double, Triple and Four Doses. Fill range depending upon vial opening and bulk density of powder. Under controlled level of Humidity (i.e. 25%) |
| Accuracy | ±1% depending upon consistency and uniformity of bulk density of Injectable powder |
| Electrical Supply | 1.00 HP For Main Drive. |
| Power Requirement | 440 Volts, 3 Phase (4 wire System) 50 Hz. |
| Height of Conveyor | Adjustable from 800 To 850 MM |
| Dimensions | 3028 mm (L) x 1093 mm (W) x 1885 mm (H) |
| Net Weight | 800 KGS. (Approx.) |
| Gross Weight | 1200 KGS. (Approx.) |
| Vial Diameter | 25 mm to 45 mm max. |
| Height | 75 mm maximum. |
| Rubber Stopper | 20 mm diameter. |
| Pneumatic Air | Filtered, oil free, sterile low pressure AIR at 2 kg/cm2 (2/3 bar) |
| Vacuum line | 20 HG. (Pump will be supplied by S.B.) |
Salient Features:
- M.S. moulded structure duly powder coated to avoid any vibration with adjustable screws to adjust conveyor height as per in feed tunnel.
- All parts and assemblies coming in contact with powder and rubber stopper are made of S.S.316 and easily removable for
- mandatory Autoclaving/ Sterilization.
- "NO VIAL, NO FILL" System eliminates wastage of costly powder.
- Spring loaded Teflon top seal for powder hopper reduces the friction between and top seal and avoid chance of white particle shading during production.
- Doctor blade and wiper blade can be adjusted from outside also without disturbing any production, which saves lot of time, powder wastage and chances of area condition disturbance.
- All assemblies under top plate are positioned as for easy cleaning or maintenance.
- Multiple dosing of Inject able powder or changeover of container size and different fill size is possible by just changing the vial separator or size of the piston respectively.
- All driving is through High quality imported Gear motor for better machine performance without vibration or leakage of oil of area floor from gear box.
- Machine speed can be adjusted through A.C. Frequency drive, which is time saving and easy to synchronize Unscrambled and scrambler speed with machine speed.
- Machine is provided with delrin conveyor belt to avoid sticking of vial on conveyor.
- Special clutch devices are provided on vial separator for safety purpose.
- Vibratory bowl for rubber Stoppering unit support to run machine with total claimed speed of machine.
- Air filter will be of S.S.316 housing with Nylon cartridge for proper removal of particle of 0.22 micron having 10" length.
- Vacuum filter will be of PVC transparent material with nylon cartage having length of 10".
- Imported Gear Motor for Main drive, Unscrambled and scrambler.
- A.C. Frequency drives for Main drive, Unscrambled and Scrambler.
- Pre and Post Gassing unit for Nitrogen or Carbon Dioxide flushing.
- Pure air filters for Air and Vacuum.
- "No Vial, No Filling System".
- "No Stopper in Chute, Machine Stop System"
- Vacuum pump.
- Acrylic Cabinet with Imported Aluminium Structure for Machine, Unscrambled and Scrambler
Applications
The Injectable Dry Powder Filling Machine with Rubber Stoppering is designed for pharmaceutical manufacturers handling sterile dry powder formulations in vials. The machine provides controlled powder dosing followed by automatic rubber stopper insertion.
Key applications include:
- Sterile Injectable Powders – Filling dry pharmaceutical powders into sterile vials.
- Antibiotic Injectables – Suitable for filling antibiotic powder formulations.
- Cephalosporin Products – Used for sterile cephalosporin powder filling applications.
- Pharmaceutical APIs – Accurate filling of sterile active pharmaceutical ingredients where applicable.
- Lyophilized Products – Suitable for vial filling applications involving sterile dry products, subject to product characteristics.
- Veterinary Injectables – Filling sterile veterinary powder formulations into vials.
- Biopharmaceutical Products – Suitable for selected sterile biological and biotech powder formulations.
- Research & Development – Useful for controlled filling of sterile injectable powders during development and scale-up.
- Frequently Asked Questions
Applications of Injectable Dry Powder Filling with Rubber Stoppering Machine
The MMC-VPF-4 Injectable Dry Powder Filling and Rubber Stoppering Machine by Bhagwati Sterifill Technologies is designed for filling sterile pharmaceutical dry powders into vials and automatically inserting rubber stoppers. The machine supports single, double, triple and four-dose filling configurations, making it suitable for different injectable powder filling requirements.
Major Applications
- Sterile Injectable Powder Filling – Accurate filling of sterile pharmaceutical powders into vials.
- Antibiotic Powder Filling – Suitable for injectable antibiotic powder formulations where the product characteristics are compatible with the dosing system.
- Cephalosporin Powder Filling – Suitable for pharmaceutical powder products requiring controlled vial filling.
- Pharmaceutical Dry Powder Filling – Designed for filling powder formulations from 50 mg to 6 g, depending on the selected dosing configuration.
- Multi-Dose Powder Filling – Double, triple and four-dose systems provide flexibility for higher filling quantities.
- Veterinary Injectable Powder Filling – Suitable for selected veterinary sterile powder formulations.
- Sterile Pharmaceutical Manufacturing – Designed for applications requiring controlled powder filling and automatic rubber stoppering.
- Injectable Vial Filling Lines – Can be incorporated into a complete vial processing line with upstream and downstream pharmaceutical equipment.
Machine Highlights
The MMC-VPF-4 Vial Filler incorporates several features designed for pharmaceutical powder filling:
- No Vial – No Fill System
- No Stopper – Machine Stop System
- Low Air – Machine Stop System
- Low Vacuum – Machine Stop System
- Built-in rubber stoppering system
- Multiple dosing system
- SS316 product-contact parts
- SS304 machine construction
- Separate variable-speed drive for powder hopper
- Completely dismantlable powder hopper for cleaning
- Reduced powder wastage
- Reduced doctor-blade and wiper-blade adjustment
- Inbuilt turntables with separate speed control
- Automatic vial infeed and exit
- Heavy-duty powder-wheel mounting
- Clutch safety system for vial breakage
- Powder hopper positioned to minimize crossover during charging
- Minimum 6-inch machine-bottom clearance
- Moving conveyor positioned above the top plate
Frequently Asked Questions – FAQ
1. What is an Injectable Dry Powder Filling Machine?
An Injectable Dry Powder Filling Machine is a pharmaceutical vial-filling machine designed to accurately dose dry powder formulations into sterile vials. The MMC-VPF-4 also incorporates an automatic rubber stoppering system for closing the filled vials.
2. What is the filling range of the MMC-VPF-4?
The machine can fill:
- 50 mg to 1.5 g in a single-dose system
- 1.5 g to 6 g using double, triple and four-dose configurations
The actual filling performance depends on the characteristics of the powder and the selected dosing arrangement.
3. What filling accuracy can be achieved?
The specified filling accuracy is ±1%, depending on the powder characteristics and controlled environmental conditions.
4. What humidity is required for the machine?
A controlled humidity level of below 30% RH is required for the filling operation. The required humidity-control arrangement is to be provided by the customer.
5. What vial sizes can the MMC-VPF-4 handle?
The specified vial diameter range is 25 mm to 38 mm, with a maximum vial height of 75 mm.
6. What rubber stopper size is used?
The specified rubber stopper diameter is 20 mm.
7. Does the machine have a No Vial–No Fill system?
Yes. The No Vial–No Fill system prevents the machine from dispensing powder when a vial is not correctly positioned at the filling station.
8. Does the machine have automatic rubber stoppering?
Yes. The MMC-VPF-4 has a built-in rubber stoppering system for automatic stopper insertion after powder filling.
9. What happens if there is no rubber stopper?
The machine incorporates a No Stopper – Machine Stop System, which stops machine operation when the required stopper condition is not available.
10. What happens if compressed-air pressure is low?
A Low Air – Machine Stop System is provided as a safety and process-control feature to stop the machine when the required compressed-air condition is not maintained.
11. What happens if vacuum pressure is low?
The machine incorporates a Low Vacuum – Machine Stop System to monitor the vacuum requirement for the powder-filling operation.
12. What materials are used for the machine?
The powder/product-contact parts are manufactured from SS316, while the main machine construction is made from SS304.
13. Can the powder hopper be removed for cleaning?
Yes. The powder hopper can be completely dismantled for easy cleaning. The machine design also minimizes crossover during powder charging.
14. Does the machine support multiple-dose filling?
Yes. The MMC-VPF-4 is available with single, double, triple and four-dose filling configurations.
15. What is the maximum production speed?
The specified maximum output is:
| Filling Configuration | Maximum Output |
|---|---|
| Single Dose | 120 vials/minute |
| Double Dose | 60 vials/minute |
| Triple Dose | 40 vials/minute |
| Four Dose | 30 vials/minute |
Bhagwati Sterifill Technologies is developing higher-speed injectable dry powder filling and rubber stoppering machines for customers requiring increased production capacity. New configurations targeting 240, 300 and 500 vials per minute are under development.
| Model / Configuration | Speed Status |
|---|---|
| Current MMC-VPF-4 | Up to 120 VPM |
| High-Speed Model | 240 VPM |
| High-Speed Model | 300 VPM |
| Ultra High-Speed Model | 500 VPM – Under Development |
Actual production output can vary depending on powder characteristics, vial handling, filling quantity and operating conditions.
16. What are the utility requirements?
The specified utilities are:
- Electrical: 415 VAC, 3 Phase + 220 VAC, Single Phase, 50 Hz
- Motor Power: 2.0 HP
- Compressed Air: Filtered, oil-free, 4 kg/cm², customer supply
- Vacuum: 28″ Hg @ 300 LPM; 500 LPM recommended
- Humidity: Below 30% RH
17. What is the model number of the machine?
The model is MMC-VPF-4.
18. What are the overall dimensions of the vial filler?
The approximate overall dimensions are:
2800 mm (L) × 840 mm (W) × 1675 mm (H).
19. Who manufactures the Injectable Dry Powder Filling Machine?
The MMC-VPF-4 Injectable Dry Powder Filling and Rubber Stoppering Machine is manufactured by Bhagwati Sterifill Technologies, serving pharmaceutical and sterile injectable manufacturing applications.
