Automatic Ampoule Filling Machine for 1–20ml Glass Ampoules with Washing Filling

This automatic ampoule filling machine is a three-in-one unit that performs ultrasonic washing, liquid filling and flame sealing for 1–20ml glass ampoules on a single frame. It suits multi-specification production where one line must switch between 1ml, 2ml, 5ml, 10ml and 20ml ampoules without mechanical rework. Changeover between sizes takes less than 30 minutes using quick-release filling needles and adjustable sealing burners.

Many filling workshops run separate washing, filling and sealing machines connected by manual trays. Operators transfer wet ampoules by hand, which risks contamination, particle ingress and scratches on the glass neck that later become sealing cracks. For plants producing multiple ampoule sizes, installing a dedicated line for each size is too expensive, and manual changeover on conventional machines can consume half a shift.

Discrete machines create open exposure windows between stations: washed ampoules sit in ambient air while waiting, filling nozzles drip between cycles, and flame sealing depends on the operator's judgement of burner height and gas flow. Size changeover on traditional equipment forces operators to swap star wheels, pistons and burner nozzles one part at a time, which multiplies downtime and setup errors.

This machine integrates washing, drying, filling and flame sealing into one closed transfer chain. Ampoules move on servo-driven star wheels, so every station aligns automatically and no manual tray handling exists between processes. A PLC stores recipe parameters for every ampoule size from 1ml to 20ml; calling a recipe repositions the filling needles, adjusts piston stroke and tunes burner gas pressure in one step. Filling accuracy remains within ±0.5% across the entire range.

• Full 1–20ml range: one machine handles 1, 2, 5, 10 and 20ml ampoules, cutting equipment cost per SKU
• Servo-driven star wheel transfer: cam indexing keeps ampoule pitch accurate and eliminates jams at high output
• PLC recipe management: stored parameters for each size reduce changeover to under 30 minutes
• ±0.5% filling accuracy: ceramic piston pumps avoid metal-to-sterile contact, protecting sensitive injections
• Flame sealing with gas monitoring: automatic flameout protection and gas pressure regulation keep seal quality consistent
• GMP-friendly construction: AISI 304/316L contact parts, CIP-compatible surfaces and an enclosed filling zone

This model is widely used for Water for Injection (WFI), normal saline, glucose solutions, vitamins, amino acids and traditional Chinese medicine injections in 1–20ml glass ampoules. It fits contract manufacturing organizations (CMOs) that run multiple small-batch products, because the recipe system switches product and size quickly without cross-contamination risk after a CIP/SIP cycle.

Typical installations include sterile plants, biological product workshops and veterinary sterile factories where output per SKU is moderate but specification variety is high. The enclosed filling zone also makes it suitable for cleanrooms rated Class 100,000 (ISO 8) or better.

First confirm your ampoule size range: if you produce only 1–2ml ampoules, a smaller dedicated machine is more economical, but if you need 1–20ml flexibility, this three-in-one configuration avoids buying three separate units. Second, calculate required output: at 12,000 pcs/h the machine covers a 50 million-unit annual volume on a single shift. Third, check liquid characteristics: for oily or highly viscous injections, specify the optional peristaltic pump heads instead of pistons. Finally, verify utilities on site, especially gas supply pressure and compressed air at 0.6–0.8 MPa, before ordering.

Q: Can one machine really handle both 1ml and 20ml ampoules without changing parts?

Yes. The star wheels, filling needles and burner nozzles are quick-release components, and the PLC recipe system repositions them automatically. A typical size changeover, including cleaning validation, takes 20–30 minutes for an experienced operator.

Q: What gas is needed for flame sealing?

LPG or natural gas with a stable supply pressure of 0.05–0.1 MPa. The machine includes an automatic gas pressure regulator and flameout protection; oxygen enrichment is optional for faster sealing of thick-walled 20ml ampoules.

Q: How is filling accuracy maintained at 12,000 pcs/h?

The ceramic piston pumps are driven by a servo motor with encoder feedback, and each head is individually calibrated. In-line check-weighing can be added as an option to reject out-of-tolerance ampoules automatically.

Q: Is the machine suitable for sterile production?

It is designed for aseptic lines: the filling zone is enclosed and can be paired with a laminar flow hood or an isolator. Surfaces are CIP-compatible, and the machine itself can be surface-sterilized with VHP in the installed position.

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.