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

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

Double the Throughput Within an Optimized Cleanroom Footprint

In large-scale sterile parenteral manufacturing, achieving relentless processing speed without sacrificing volumetric dosing precision is an ongoing engineering challenge. The Harsiddh Automatic Double Wheel Injectable Dry Powder Filler & Stoppering Machine solves this by engineering high-speed throughput and strict aseptic controls into a single, compact, cGMP-compliant monoblock platform.

Designed specifically for pharmaceutical lines handling 5ml to 30ml (expandable up to 100ml) glass vials, this advanced system utilizes an innovative twin-wheel layout to double the output of conventional single-wheel designs—without expanding your valuable cleanroom or Laminar Air Flow (LAF) footprint. Operating on a proven vacuum-and-piston volumetric principal alongside integrated nitrogen flushing, it guarantees uncompromised dosing accuracy for expensive antibiotic and sterile powder formulations.

Strategic Benefits & ROI Highlights

• Twin-Wheel Production Velocity: The synchronized double-wheel configuration effortlessly doubles your hourly output, making it an elite choice for high-volume commercial batches.
• Exceptional Dosing Precision: Operating via adjustable piston depths inside the powder wheel ports, the system maintains a tight filling accuracy tolerance of just ±1%, protecting high-value formulations from product giveaway.
• Monoblock Aseptic Design: Integrating powder dosing and rubber stoppering within immediate proximity minimizes the critical window that open vials are exposed to the environment, reducing LAF infrastructure overheads.
• Smart Material Protection: Standardized with an electronic “No Vial – No Filling” and “No Vial – No Stoppering” proximity array that completely bypasses empty conveyor pockets to eliminate powder waste or component jamming.
• Low-Resonance Framework: Fabricated on a heavy-duty stainless steel square pipe chassis equipped with vibration-absorbing leveling pads to ensure stable, continuous high-speed runs without vial breakages.

The Continuous Automated Processing Cycle

The system executes a fully automated, continuous mechanical loop that safely synchronizes vial transit, twin-wheel micro-dispensing, and immediate rubber bung application:

[Rotary In-Feed Table] ➔ [1. SS Conveyor Transit] ➔ [2. Dual-Chamber Vacuum Dosing] ➔ [3. Smart Sensor Check] ➔ [4. Vibratory Stoppering] ➔ [5. Out-Feed Turn Table]

1. Automated In-Feed & Conveyor Transit

Sterile vials index systematically from a rotary turn table onto a high-quality SS flat conveyor track. To safeguard against upstream line backpressures, an integrated mechanical safety clutch system halts conveyor drives instantly if a tipping risk or structural jam is detected.

2. Dual Volumetric Vacuum Filling

Sterile bulk powder is housed inside dual-chamber hoppers, continuously turned by mechanical agitators to maintain uniform bulk density and eliminate clumping. As the twin wheels rotate, an internal vacuum system draws the exact dose into designated wheel ports. Precision-machined doctor blades scrape away any excess overfill from the wheel’s face before specialized pneumatic pulses cleanly discharge the metered powder into the vials.

3. Real-Time Smart Monitoring

Before advancing to the sealing station, vials pass beneath an array of synchronized proximity sensors. If a missing container or line gap is detected, the machine’s control logic initiates a selective bypass command, ensuring that the filling and stoppering heads do not actuate during that specific mechanical pulse.

4. Precision Rubber Stoppering

Immediately following the filling stage, the open vials advance beneath a synchronized, low-noise vibratory rubber stopper bowl feed system. The 20mm rubber bungs are oriented along an SS316 track and pressed firmly onto the vial necks via a pneumatic pick-and-place mechanism, sealing the formulation instantly.

5. Contamination-Free Discharge

Once hermetically sealed, the stabilized vials are smoothly swept off the linear conveyor track and guided onto an out-feed rotary turn table, organized and ready for downstream automatic aluminum capping and final optical inspection.

Global cGMP Compliance & Premium Construction

Toolless, Autoclavable Change Parts

To combat cross-contamination, all product-contact components—including the dual powder hoppers, mechanical stirrers, scraping doctor blades, and stopper delivery chutes—are machined from premium AISI 316 Stainless Steel. Every contact part is engineered for rapid, toolless disassembly to undergo standard cleanroom autoclaving or Cleaning-in-Place (CIP) routines.

Advanced PLC Touchscreen Integration

The machine’s dual-wheel kinematics and indexing mechanisms are perfectly synchronized via central PLC automation. Cleanroom operators can easily manage individual wheel vacuum pressures, fine-tune dosing depths, adjust conveyor tracking speeds, and review real-time batch diagnostics via an intuitive, multi-lingual touchscreen HMI panel.

Technical Specification

Specification	Details (HPF-240 Series)
Model Number	HPF-240 (Double Wheel & Hopper)
Production Output	80 to 240 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	± 1.0% (Subject to Bulk Density & Humidity)
Main Drive	3 H.P. High-Performance Motor with VFD
Contact Parts	Stainless Steel AISI 316L
Machine Dimensions	3650mm (L) X 1000mm (W) X 1700mm (H)

Why Choose Harsiddh Unimach Private Limited?

With over three decades of engineering expertise based in Ahmedabad, India, Harsiddh Unimach Private Limited stands as a globally recognized manufacturer and exporter of advanced pharmaceutical packaging equipment. Our ISO 9001:2015 certified production processes utilize premium imported gearboxes, heavy-duty electrical contactors, and robust overload relays to guarantee unparalleled equipment lifespan and zero operational breakdown risks.

Whether you are expanding an antibiotic injectables filling facility or upgrading an analytical R&D pilot plant, our custom-engineered machinery provides the precise automated execution your operations demand. We supply worldwide to markets across North America, Europe, the Middle East, Asia, and Latin America with comprehensive export-grade wooden packaging and responsive after-sales technical field support.

For official inquiries, layout planning documents, or custom change-part options for the Automatic Double Wheel Injectable Dry Powder Filling & Stoppering Machine, contact our global sales department at info@harsiddhunimach.com or submit an instant quote request via our official webpage.