High Efficiency Ampoule Filling Machine for 20ml Ampoules with Washing Filling

This high efficiency ampoule filling machine is dedicated to 20ml ampoules, the largest common ampoule format, used for infusion concentrates, large-dose antibiotics and veterinary preparations. Large ampoules are disproportionately difficult: the glass wall is thicker, the liquid column is heavier, and the sealing neck has high thermal mass. This machine is engineered around those three facts rather than treating 20ml as an afterthought on a universal line.

Producers running 20ml ampoules on universal machines accept three penalties: reduced speed (often below 5,000 pcs/h), higher sealing defects from under-heated thick necks, and filling inaccuracy because large pistons stroke near their limits. When 20ml volume is a major share of production, these penalties translate into real capacity shortages and rejected batches.

Universal machines compromise on station geometry: star wheel pockets sized for small ampoules grip a 20ml body poorly, the washing nozzle array does not cover the full 55–65mm body length, and the burner flame profile cannot deliver enough heat to the thick neck without overheating the shoulder. Filling large volumes also requires slower pump cycles, which the line speed cannot accommodate.

This machine uses 20ml-specific tooling throughout: deep pocket star wheels with body support rails, full-length washing nozzles, and a high-output burner with a shaped flame that concentrates heat on the neck while a cooling air ring protects the shoulder. The filling station uses large-bore ceramic pistons with a servo profile tuned for 20ml delivery, holding ±0.5% accuracy at 7,000 pcs/h, roughly 40% faster than a universal machine on this format.

• 7,000 pcs/h on 20ml format: about 40% faster than universal machines on large ampoules
• Full-length washing coverage: nozzles sized for 55–65mm ampoule bodies
• Shaped-flame burner: heat concentrated on the neck, cooling air ring protects the shoulder
• Large-bore servo pistons: 20ml-tuned pump stroke with ±0.5% accuracy
• Deep-pocket star wheels: body support rails prevent tilting of tall ampoules
• Heavy-duty construction: reinforced frame for the higher torque of large-format rotors

This machine fits producers of 20ml infusion concentrates, large-dose antibiotics, amino acid solutions and veterinary injectables, where the large format dominates the portfolio. It is also used by CMOs that win 20ml contracts but cannot serve them profitably on general-purpose lines. The 10–30ml extended option covers specialty formats for diagnostic reagents and contrast media.

Because 20ml ampoules are heavier, the machine includes a reinforced outlet conveyor that feeds downstream inspection and packaging without sagging or jams.

Verify that 20ml is truly your dominant format; if smaller sizes share the line, a universal machine with 20ml tooling may be more flexible, though slower. Second, check the ampoule body length, because suppliers' 20ml ampoules vary from 55mm to 65mm and the washing nozzles and star wheels must match your exact drawing. Third, confirm your sealing gas supply, as the high-output burner consumes about 1.5 m³/h. Finally, request a full-speed FAT with your own 20ml ampoules, including a leak test sample of 200 units per hour.

Q: Why is this machine faster on 20ml than a universal line?

Universal lines limit speed because their sealing burner cannot fuse the thick 20ml neck within a short cycle. Our shaped-flame burner with shoulder cooling completes a secure seal in about 1.2 seconds, allowing 7,000 pcs/h instead of the typical 4,000–5,000 pcs/h.

Q: Can it handle 30ml ampoules?

The extended configuration supports up to 30ml at about 5,000 pcs/h. This requires larger star wheels, a stronger burner and a longer washing nozzle set, all available as factory options.

Q: How is filling accuracy maintained at large volumes?

The large-bore pistons are servo-driven with a dual-speed profile: fast fill to 90% of volume, then slow finish to the target. This eliminates overshoot, which is the main accuracy problem on large fills.

Q: What is the typical seal rejection rate on 20ml?

With the shaped-flame burner and correct gas supply, seal-related rejection is typically 0.3–0.5%, compared with 1–2% on universal machines. The leak test sampling rate is adjustable up to 100% for critical products.

Every machine is test-run with water and dummy ampoules for 72 hours before packing, and a sealed calibration report is shipped with the unit. The machine is wrapped in anti-rust film and secured in an export-grade wooden case with foam inserts, suitable for sea or air freight. We supply CE, GMP and ISO 9001 documentation, a 12-month warranty on parts, and lifetime remote technical support. On-site installation, operator training and IQ/OQ/PQ validation assistance are available on request.