What Is a Vial Powder Filling Machine?
A vial powder filling machine is one of the most efficient machines for injectable glass vials. It uses a conveyor with a filling head to accurately fill the vials.
It is equipped with a safety guard for the conveyor gearbox, motor and pneumatic cylinders to protect components from damage and extend their life. It delivers a single dose of filling with a filling accuracy of +/- 1%.
Filling
A vial powder filling machine dispenses sterilized powder through a set of mechanical systems. The system includes a powder hopper fitted with a powder wheel with eight ports that have vacuum plates and pistons to adjust the amount of powder that is being fed. The powder is then pumped into the vial while excess materials are scrapped off with a doctor blade.
Various performance classes of vial powder filling machines can achieve up to 600 vials per minute. The single-disc sealing principle of these machines ensures low particle levels and minimal process risk.
These machines can be used for both sterile and non-sterile products, and are suitable for small productions of pharmaceuticals. They are also durable and easy to maintain.
The filling nozzles of this machine are made from stainless steel for cGMP compliance. They are surrounded by a rubber seal that prevents dust from entering the nozzle. The nozzles are then positioned above a powder wheel.
Vial syringes are provided and they can be used for different types of liquids. They have a safety clutch to prevent breakage of vials during the process.
To ensure proper placement of the vials, an in-feed turn table is provided with guides. The incoming dry sterilized and vial powder filling machine siliconised vials are guided into the machine by this turn table.
This step is a key component of the vial powder filling process. If the vials are not placed correctly, they can cause contamination and delays in the process. This can negatively impact the overall production.
Another factor to consider is that the correct amount of liquid needs to be added to each container. Having the wrong level of liquid in each vial can cause flooding and product waste.
One of the best ways to avoid these issues is to use a flood rule that can control the amount of liquid that is added to each container. This can help to reduce the number of vials that are filled, as well as reduce the time spent filling them.
Besides the above-mentioned factors, there are several other problems that can occur during the filling process. Some of these include improper filling, jams, and excess liquid. These problems can lead to production delays and even a loss of product.
Stoppering
Stoppering a vial powder filling machine is an important step that must be done correctly. The process involves adding a rubber stopper to the bottom of the vial. This stops the flow of powder and prevents leakage. It also reduces potential for contamination, a major concern in a sterile environment.
The two most common methods of stoppering a vial are vented placement and vacuum placement. Vented placement is typically preferred for injectable drugs that require an air bubble, such as ophthalmic medicines. It is considered the most reliable and repeatable method, says Jackson.
Another stoppering technique is vacuum placement, which uses a vacuum to pull a stopper into the tube of a prefilled syringe. This method is preferable for viscous and protein-based pharmaceuticals because it eliminates the risk of oxygen interacting with the drug, he says.
During the stoppering process, the vial is sent to the Stoppering Unit. The unit consists of a vibratory bowl with support guide, a star wheel and a sterilized rubber stopper.
When the vial is placed in the chute, the stopper bung is delivered to the vial through the delivery chute. It is pressed into place by the star wheel and then it further moves on the conveyor to the next stoppering operation.
Once the vial is finished stoppering, it is transferred to the filling unit. It is filled with the desired powder, which is dispensed through a piston assembly.
The powder is then sucked through the product wheel. It is then dispensed into the vial, which is then fed onto the conveyor.
If there is a need for additional sealing, the vial is then collected on an out-feed star wheel and moved to the next sealing operation. The vials can then be used for the final processing steps, such as a cap-sealing machine.
The FreeZone stoppering tray dryer lyophilizes moderate to large loads of vials and seals them under vacuum. It offers temperature control from -40 to +40deg C and can be equipped with a 6-port manifold, isolation valve or sample trays. It is HCFC/CFC-free and features an electric heater that cools and heats the fluid medium to maintain shelf temperatures within +-1deg C.
Sealing
A vial powder filling machine is an automatic machine that allows you to place dry powder in glass vials. These machines are used for a wide range of applications. They can be found in pharmaceutical, cosmetics, and many other industries.
These machines use a series of filling heads to accurately fill the vials. They also have a conveyor belt that transports the vials to the head of the machine.
This machine can process up to 120 vials per minute. It is made from SS316 materials and can handle different kinds of powders. It is available with different features, including a turn table at the infeed and outfeed, as well as a rubber stopper feeding bowl.
The vials are placed on the conveyor, which will then be transferred to the filling station. They are then filled with the desired powder and sealed with a rubber stopper. The machine can also be configured to automatically finish a number of procedures, such as nitrogen blanketing and capping.
One of the most important parts of a vial powder filling machine is its vacuum system. This allows you to safely and accurately fill and seal vials with powder.
You can choose a system that uses mechanical oepration or a servo-based system. The servo-based system is a more accurate option, as it allows you to adjust the rotation of the powder wheel.
A servo-based system also allows you to adjust the amount of pressure that the vials are exposed to. This will ensure that you get the best results possible.
Another feature that you can find in a vial powder filling machine is a sensor. This will allow you to set a certain amount of pressure that the machine can hold before it stops working. This will help you to protect your product from damage and increase the safety of the machine.
This is especially important for glass vials, as it will keep them from being damaged by the liquid. This will make sure that your product is safe to use and that it will stay intact for a long time.
Washing
When a vial powder filling machine needs to be cleaned, it must be washed with water. This is a necessary step because it removes the particles that are on the glass surface and prevents them from getting inside the containers during the processing process.
The water used in this step should be sterile and oil-free to reduce the risk of cross contamination. The process must also be performed at low temperatures to preserve the contents of the vials.
Washing a vial powder filling machine can be done manually or automatically. If you are washing it by vial powder filling machine hand, be sure to use a disinfectant solution. You should also wipe the machine base with a sponge soaked in disinfectant solution.
A vial powder filling machine should be washed regularly to ensure that it is clean and free of any bacteria or other microorganisms. This will help to prevent damage to the machine and ensure that it is functioning properly.
If you are using a vial powder filling machine that is automatic, it will need to be washed at least once per week. This will help to ensure that the machine is working as it should be and that it is not causing any problems for your company or customers.
To wash the vial powder filling machine, you must dismantle it and clean the main hopper, intermediate hopper and rubber stopper hopper. You should also clean the out feed and the pumping station with water for injection.
Once you have completed the cleaning process, it is time to dry the vials. This will help to keep them safe from contaminating agents and make them easier to store and transport.
The drying section of the machine is designed to ensure that the vials are completely dry before they can be refilled. The drying process is also designed to reduce the amount of moisture that is on the outside of the containers.
A vial powder filling machine should be rinsed at least once a week to remove the particles that are on the glass surface and to prevent them from getting inside the containers during the processing. This will help to prevent damage to the container and ensure that it is functioning properly.
