Injectable Liquid Filling & Stoppering Machine (Servo Base)

Overview of the injectable liquid filling and stoppering machine

The injectable liquid filling and stoppering machine represents a pivotal advancement in pharmaceutical manufacturing. This state-of-the-art equipment ensures that injectable liquids are precisely filled into vials, maintaining sterility and accuracy throughout the process. By automating the filling and stoppering stages, the machine significantly reduces the risk of contamination, ensuring that the final product meets stringent pharmaceutical standards.

Historically, the evolution of liquid filling technology has transitioned from manual operations to sophisticated automated systems, improving efficiency and consistency. This machine's integration into production lines symbolizes a leap forward in achieving high-volume production without compromising on quality.

Its design caters to the ever-increasing demand for precision and reliability in the pharmaceutical industry, making it an indispensable asset for manufacturers. Moreover, the machine's ability to handle various vial sizes and stopper types highlights its versatility, accommodating a wide range of products. This flexibility ensures that pharmaceutical companies can streamline their operations and respond swiftly to market demands.

Overall, the injectable liquid filling and stoppering machine epitomizes the blend of technological innovation and practical application, setting a new benchmark in pharmaceutical manufacturing.

Key components and features

The servo base injectable liquid filling and stoppering machine boasts several key components that contribute to its superior performance and reliability. Central to its design is the servo motor, which ensures precise control over the filling and stoppering processes. This motor's integration with the PLC (Programmable Logic Controller) system allows for seamless automation and real-time adjustments, enhancing the machine's efficiency.

The stainless steel construction not only provides durability and ease of cleaning but also ensures compliance with strict hygiene standards required in pharmaceutical environments. Additionally, the machine features a stainless steel slat conveyor, which facilitates the smooth and continuous movement of vials through various stages of filling and stoppering.

The reciprocating nozzle with self-centering devices guarantees accurate filling by maintaining alignment with each vial. The SS syringe assembly, another critical component, works on volumetric principles to ensure consistent liquid filling.

A notable feature is the "No vial, no filling" system, which prevents wastage and ensures that the filling process only occurs when a vial is correctly positioned. This combination of advanced components and innovative features underscores the machine's capability to deliver high-precision filling and stoppering, making it an essential tool for modern pharmaceutical manufacturing.

Working Principles

Volumetric filling principles

The volumetric filling principle is fundamental to the operation of the injectable liquid filling and stoppering machine. This method ensures that each vial receives an exact volume of liquid, which is critical for maintaining dosage accuracy in pharmaceutical products. The process begins with the liquid being drawn into the syringe assembly through a precisely controlled mechanism.

The servo motor-driven pistons then dispense the liquid into the vials with impeccable accuracy. The use of diving nozzles helps to minimize splashing and foaming, ensuring that the filling process is clean and efficient. This approach is particularly beneficial for handling high-viscosity liquids and those that are sensitive to aeration.

By employing volumetric filling, manufacturers can achieve a high degree of consistency and repeatability, which is essential for meeting regulatory standards and ensuring patient safety. Additionally, the ability to adjust the fill volume easily through the servo system allows for quick and flexible production changes, catering to different product requirements.

Overall, the volumetric filling principle not only enhances the precision of the filling process but also contributes to the operational efficiency and versatility of the machine.

Compact and versatile design

The compact and versatile design of the injectable liquid filling and stoppering machine is one of its standout features, making it suitable for a variety of production environments. Its streamlined footprint allows it to be integrated into existing production lines without requiring extensive modifications or additional space.

This compactness is especially advantageous for facilities with limited floor space, enabling them to maximize their production capacity. Despite its small size, the machine is incredibly versatile, capable of handling different vial sizes and types of injectable liquids. The versatility extends to its ability to perform both full and half stoppering operations, catering to a wide range of pharmaceutical products.

This adaptability ensures that the machine can meet diverse production needs, from small batch runs to large-scale manufacturing. The stainless steel construction and modular design also contribute to its ease of maintenance and cleaning, ensuring that it meets the stringent hygiene standards of the pharmaceutical industry.

By combining a compact footprint with versatile functionality, this machine offers a practical and efficient solution for modern pharmaceutical manufacturing, enabling companies to enhance their production capabilities while maintaining high standards of quality and safety.

Components and Operation

Injectable Liquid Filling Stoppering Machine

Stainless steel slat conveyor

The stainless steel slat conveyor is a critical component of the injectable liquid filling and stoppering machine, playing a crucial role in ensuring smooth and efficient operation. This conveyor system is designed to transport vials seamlessly through the various stages of the filling and stoppering process.

Made from high-grade stainless steel, the slat conveyor is not only durable but also resistant to corrosion and easy to clean, making it ideal for use in sterile pharmaceutical environments. The conveyor's design ensures that vials are accurately positioned and moved at a consistent speed, which is essential for maintaining the precision of the filling process.

Additionally, the slat conveyor can be adjusted to accommodate different vial sizes, enhancing the machine's versatility. Its robust construction minimizes downtime and maintenance requirements, contributing to the overall efficiency of the production line. The smooth movement provided by the slat conveyor helps prevent any spillage or breakage of vials, ensuring that the liquid filling process remains clean and efficient.

Overall, the stainless steel slat conveyor is a vital element that enhances the reliability and performance of the injectable liquid filling and stoppering machine, supporting high-quality pharmaceutical production.

Reciprocating nozzle with self-centering devices

The reciprocating nozzle with self-centering devices is a pivotal feature of the injectable liquid filling and stoppering machine, ensuring precise and consistent filling of vials. This advanced nozzle system is designed to move in a reciprocating motion, allowing it to align perfectly with each vial before dispensing the liquid.

The self-centering mechanism ensures that the nozzle maintains its position relative to the vial, preventing any misalignment that could lead to spillage or inaccurate fills. This feature is particularly beneficial when dealing with high-speed production lines, where precision is critical to maintaining product quality.

The reciprocating motion of the nozzle also helps in minimizing foam and splashes, which can be a concern when filling certain types of liquids. By reducing the risk of contamination and ensuring uniform filling, this system significantly enhances the overall efficiency and reliability of the machine.

Additionally, the self-centering devices facilitate easy adjustment and maintenance, allowing operators to quickly adapt the machine to different vial sizes and fill volumes. This flexibility makes the reciprocating nozzle system an indispensable component for modern pharmaceutical manufacturing, ensuring that each vial is filled accurately and efficiently.

SS syringe assembly

The SS (stainless steel) syringe assembly is at the heart of the injectable liquid filling process, ensuring that each vial is filled with the precise amount of liquid required. This assembly includes several key components: a piston, cylinder, liquid inlet and outlet assembly, and syringe fitting assembly.

The piston, driven by a servo motor, operates in a reciprocating mechanism to draw in and dispense the liquid with high precision. During one cycle, the piston pulls the liquid from the inlet nozzle, and in the next cycle, it discharges the liquid into the vial. This controlled movement ensures that the exact volume of liquid is delivered each time, maintaining consistency across all vials.

The use of stainless steel for the syringe assembly ensures durability and resistance to corrosion, which is essential for maintaining hygiene and preventing contamination. The syringe assembly's design allows for easy cleaning and sterilization, making it suitable for use in sterile pharmaceutical environments.

Additionally, the assembly can be quickly adjusted to accommodate different fill volumes, providing flexibility for various production needs. Overall, the SS syringe assembly plays a crucial role in the reliability and accuracy of the injectable liquid filling and stoppering machine, ensuring that each vial is filled to the exact specifications required.

No vial, no filling system

The "No vial, no filling" system is a critical safety and efficiency feature of the injectable liquid filling and stoppering machine. This system ensures that the filling process only occurs when a vial is correctly positioned under the filling nozzle, preventing wastage and contamination.

If a vial is missing or not properly aligned, the system automatically halts the filling operation, ensuring that no liquid is dispensed without a vial in place. This feature not only saves valuable product but also protects the machine and production line from potential damage caused by spills or overflows. The "No vial, no filling" system is integrated with the machine's PLC control, allowing for real-time monitoring and adjustments.

This ensures seamless operation and minimizes downtime, enhancing the overall efficiency of the production process. Additionally, this system contributes to maintaining a sterile and clean environment, which is essential in pharmaceutical manufacturing.

By preventing unnecessary filling and reducing the risk of contamination, the "No vial, no filling" system plays a vital role in ensuring the quality and safety of the final product. This feature underscores the machine's advanced design and commitment to precision in pharmaceutical manufacturing.

Injectable Liquid Filling Stoppering Machine Servo Base

Servo Motor and PLC Control

Servo motor control is a cornerstone of the injectable liquid filling and stoppering machine, providing the precision and reliability needed for high-quality pharmaceutical production. The servo motor is responsible for driving the pistons in the syringe assembly, ensuring that each movement is exact and repeatable.

This level of control is crucial for maintaining consistent fill volumes across all vials. By adjusting the servo motor settings, operators can easily change the fill volume to accommodate different product specifications, enhancing the machine's versatility. The servo motor's integration with the PLC (Programmable Logic Controller) system allows for real-time monitoring and adjustments, ensuring that the machine operates smoothly and efficiently.

This integration also facilitates the synchronization of the filling and stoppering processes, minimizing the risk of errors and improving overall production efficiency. The servo motor's precision and reliability contribute to the machine's ability to handle high-speed production lines without compromising on accuracy.

This advanced control system ensures that each vial is filled to the exact specifications required, maintaining the high standards of quality expected in pharmaceutical manufacturing. Overall, the servo motor control is a critical component that enhances the performance and versatility of the injectable liquid filling and stoppering machine.

PLC control system

The PLC (Programmable Logic Controller) control system is integral to the automation and efficiency of the injectable liquid filling and stoppering machine. This advanced control system allows for precise regulation of all machine operations, from the movement of the conveyor to the filling and stoppering processes.

By programming the PLC, operators can set specific parameters for each stage of production, ensuring that the machine performs consistently and accurately. The PLC control system enables real-time monitoring and adjustments, allowing for immediate responses to any issues that may arise during operation. This capability is essential for maintaining high levels of productivity and minimizing downtime.

Additionally, the PLC system supports the integration of various safety features, such as the "No vial, no filling" system, ensuring that the machine operates within safe and controlled parameters. The user-friendly interface of the PLC control system simplifies the operation and maintenance of the machine, making it accessible to operators with varying levels of expertise.

By enhancing the machine's automation and control capabilities, the PLC system plays a vital role in ensuring the reliability and efficiency of the injectable liquid filling and stoppering machine, making it an indispensable tool for modern pharmaceutical manufacturing.

Liquid Filling Unit: Syringe Assembly

The syringe assembly in the injectable liquid filling and stoppering machine operates on a fundamental principle designed to ensure precise and consistent filling of vials. At the core of this system is the reciprocating mechanism, which uses a piston and cylinder to draw in and dispense the liquid.

During the filling cycle, the piston moves downward, creating a vacuum that pulls the liquid into the cylinder through the inlet nozzle. As the piston moves upward, it pushes the liquid out of the cylinder and through the outlet nozzle into the vial.

This controlled movement ensures that each vial receives the exact volume of liquid specified, maintaining consistency across all filled vials. The servo motor-driven mechanism allows for precise control over the piston's movement, enabling operators to adjust the fill volume easily. This flexibility is crucial for accommodating different product requirements and ensuring accurate dosing.

The syringe assembly's design also facilitates easy cleaning and maintenance, which is essential for maintaining hygiene and preventing contamination. By adhering to these principles, the syringe assembly ensures that the injectable liquid filling and stoppering machine delivers high-precision filling, supporting the production of high-quality pharmaceutical products.

Reciprocating mechanism

The reciprocating mechanism in the injectable liquid filling and stoppering machine is a critical component that ensures the precise and consistent filling of vials. This mechanism operates by moving the piston in a back-and-forth motion, driven by a servo motor, to draw in and dispense the liquid.

During the filling cycle, the piston moves downward, creating a vacuum that pulls the liquid into the cylinder through the inlet nozzle. In the subsequent cycle, the piston moves upward, pushing the liquid out of the cylinder and into the vial through the outlet nozzle. This reciprocating action allows for precise control over the fill volume, ensuring that each vial receives the exact amount of liquid required.

The servo motor's role in driving the reciprocating mechanism is crucial, as it provides the precision and reliability needed for accurate filling. The ability to adjust the stroke volume through the servo system adds to the machine's versatility, allowing operators to accommodate different product specifications with ease.

The reciprocating mechanism's design also minimizes the risk of spillage and contamination, ensuring that the filling process is clean and efficient. Overall, the reciprocating mechanism is a vital component that enhances the performance and reliability of the injectable liquid filling and stoppering machine.

Rubber Stoppering Unit

Vacuum-based pick and place system

The vacuum-based pick and place system is a sophisticated feature of the injectable liquid filling and stoppering machine, designed to ensure the precise and efficient placement of rubber stoppers into vials. This system operates by using a vacuum to pick up rubber stoppers from a feeder bowl and place them accurately onto the vials.

The vibratory bowl feeder aligns the stoppers in the correct orientation, feeding them into a chute that delivers them to the stopper holding plate. The vacuum then holds the stoppers in place as the plate moves over the vials. When the vial is in position, a cam mechanism lifts the vial to meet the stopper, pressing it into the vial's neck. Once the stopper is securely in place, the vacuum is released, completing the stoppering process.

This method ensures that each stopper is placed accurately and securely, minimizing the risk of contamination and ensuring product integrity. The vacuum-based system is also capable of performing half stoppering operations, providing flexibility for different product requirements. By utilizing this advanced technology, the machine ensures that the stoppering process is efficient and reliable, contributing to the overall quality and safety of the pharmaceutical products.

Vibratory bowl feeder

The vibratory bowl feeder is an essential component of the rubber stoppering unit in the injectable liquid filling and stoppering machine, playing a crucial role in ensuring the smooth and efficient delivery of rubber stoppers to the stoppering mechanism. This feeder operates by using vibrations to align and feed rubber stoppers into the chute, ensuring that they are correctly positioned for the pick and place system.

The bowl's design and vibration frequency can be adjusted to accommodate different sizes and types of stoppers, enhancing the machine's versatility. The vibratory bowl feeder's ability to handle high volumes of stoppers efficiently makes it ideal for large-scale pharmaceutical production. By continuously feeding stoppers into the chute, the feeder ensures that the stoppering process remains uninterrupted, maintaining high production speeds.

The precise alignment provided by the vibratory bowl feeder also reduces the risk of misalignment and jams, ensuring that each stopper is delivered accurately to the stopper holding plate. Overall, the vibratory bowl feeder is a vital component that enhances the reliability and efficiency of the rubber stoppering unit, supporting the machine's ability to deliver high-quality and consistent pharmaceutical products.

Stopper holding plate

The stopper holding plate is a critical component in the rubber stoppering unit of the injectable liquid filling and stoppering machine, designed to ensure the precise placement of rubber stoppers into vials. This plate operates by using a vacuum system to hold the stoppers in place as they are moved over the vials.

The vacuum creates a secure grip on the stoppers, preventing them from shifting or falling out of position during the movement. As the stopper holding plate aligns with the vial, a cam mechanism lifts the vial to meet the stopper, pressing it into the neck of the vial. This action ensures that each stopper is placed accurately and securely, maintaining the sterility and integrity of the product.

The stopper holding plate's design allows for easy adjustment to accommodate different stopper sizes and types, enhancing the machine's versatility. Additionally, the vacuum system can be configured for half stoppering operations, providing flexibility for various product requirements. By ensuring precise and reliable stoppering, the stopper holding plate plays a vital role in the overall performance of the injectable liquid filling and stoppering machine, contributing to the production of high-quality pharmaceutical products.

Technical details of the machine

The technical specifications of the injectable liquid filling and stoppering machine provide a comprehensive overview of its capabilities and performance. The machine's dimensions and weight are designed to ensure a compact and robust structure, allowing for easy integration into existing production lines. It typically measures around 1800 mm in length, 1200 mm in width, and 1600 mm in height, with a weight of approximately 1000 kg.

The machine operates on a power supply of 220V, 50Hz, and requires a power consumption of about 3 kW. It is equipped with a stainless steel slat conveyor that can handle vials with a diameter ranging from 16 mm to 52 mm and a height of 35 mm to 110 mm.

The filling unit can accommodate a fill volume of 1 ml to 100 ml, with a filling accuracy of ±1%. The stoppering unit can handle both full and half stoppering operations, providing flexibility for different product requirements. The machine's production capacity ranges from 80 to 200 vials per minute, depending on the fill volume and vial size. These technical details highlight the machine's efficiency, precision, and versatility, making it an essential tool for high-quality pharmaceutical manufacturing.

Performance metrics

The performance metrics of the injectable liquid filling and stoppering machine are critical indicators of its efficiency, accuracy, and reliability in pharmaceutical production. One of the key metrics is the machine's production capacity, which ranges from 80 to 200 vials per minute, depending on the fill volume and vial size.

This high throughput ensures that manufacturers can meet large-scale production demands while maintaining consistent quality. Another important metric is the filling accuracy, which is typically ±1%. This level of precision is essential for ensuring that each vial contains the exact amount of liquid required, maintaining dosage accuracy and product consistency.

The machine's stoppering accuracy is also a crucial performance metric, as it ensures that each rubber stopper is placed correctly and securely, preserving the sterility and integrity of the product. Additionally, the machine's downtime and maintenance requirements are important considerations, as they impact overall productivity and operational efficiency.

The use of servo motors and PLC control systems enhances the machine's reliability and reduces the need for frequent adjustments and repairs. These performance metrics demonstrate the machine's capability to deliver high-quality and consistent results, supporting the production of safe and effective pharmaceutical products.

Applications in Pharmaceutical Manufacturing

Common applications

The injectable liquid filling and stoppering machine finds numerous applications in pharmaceutical manufacturing, playing a pivotal role in the production of various injectable products. It is widely used for filling and stoppering vials containing vaccines, antibiotics, biologics, and other sterile injectable solutions.

The machine's ability to handle different vial sizes and fill volumes makes it versatile for producing a wide range of products, from small-volume pediatric vaccines to large-volume antibiotic injections. Its high precision and accuracy ensure that each vial is filled with the correct dosage, maintaining product efficacy and patient safety.

The machine is also suitable for filling high-viscosity liquids and products that require careful handling to prevent contamination. Its advanced stoppering system ensures that rubber stoppers are placed securely, preserving the sterility of the injectable products. Additionally, the machine's ability to perform both full and half stoppering operations provides flexibility for different packaging requirements.

By automating the filling and stoppering processes, the machine enhances production efficiency, reduces labor costs, and minimizes the risk of human error. Overall, the injectable liquid filling and stoppering machine is an indispensable asset in pharmaceutical manufacturing, supporting the production of a diverse range of high-quality injectable products.

Benefits for pharmaceutical companies

Pharmaceutical companies greatly benefit from the integration of the injectable liquid filling and stoppering machine into their production lines. One of the primary advantages is the significant increase in production efficiency. The machine's high-speed operation, capable of filling and stoppering up to 200 vials per minute, enables companies to meet large-scale production demands and reduce lead times.

The automation of the filling and stoppering processes minimizes the need for manual intervention, reducing labor costs and the risk of human error. The machine's precision and accuracy ensure that each vial is filled with the exact dosage required, maintaining product consistency and meeting stringent regulatory standards.

The advanced servo motor and PLC control systems enhance the machine's reliability and ease of operation, allowing for real-time monitoring and adjustments. This capability ensures that any issues can be addressed promptly, minimizing downtime and maintaining continuous production.

Additionally, the machine's versatility in handling different vial sizes and stopper types allows pharmaceutical companies to produce a wide range of injectable products on a single machine, optimizing their production capabilities. Overall, the injectable liquid filling and stoppering machine provides pharmaceutical companies with a reliable, efficient, and cost-effective solution for high-quality injectable product manufacturing.

FAQs - Injectable Liquid Filling & Stoppering Machine

A servo base liquid filling machine offers several key advantages, including high precision, efficiency, and flexibility. The servo motor control ensures accurate and repeatable filling volumes, essential for maintaining product consistency and meeting regulatory standards. The machine's automation capabilities reduce the need for manual intervention, minimizing the risk of human error and labor costs. Additionally, the servo system allows for quick and easy adjustments to the fill volume, accommodating different product specifications and enhancing production versatility. The machine's advanced control system enables real-time monitoring and adjustments, ensuring smooth and efficient operation. Overall, the servo base liquid filling machine provides a reliable and cost-effective solution for high-quality pharmaceutical production.

The "No vial, no filling" system is a safety feature that prevents the machine from dispensing liquid if a vial is not correctly positioned under the filling nozzle. This system uses sensors to detect the presence and position of each vial. If a vial is missing or not properly aligned, the system halts the filling operation, ensuring that no liquid is wasted and preventing contamination. This feature helps maintain a clean and efficient production process, protecting the machine and production line from potential damage caused by spills or overflows. By ensuring that the filling process only occurs when a vial is in place, the "No vial, no filling" system enhances the reliability and safety of the machine.

Maintaining the stainless steel components of the injectable liquid filling and stoppering machine is essential for ensuring its durability and performance. Regular cleaning is necessary to prevent contamination and maintain hygiene standards. This includes wiping down the stainless steel surfaces with appropriate cleaning agents and ensuring that all residue is removed. Periodic inspections should be conducted to check for signs of wear or damage, particularly on moving parts such as the slat conveyor and syringe assembly. Lubricating these components as needed can help reduce friction and extend their lifespan. Additionally, operators should follow the manufacturer's guidelines for routine maintenance and servicing, including checking and replacing seals, gaskets, and other critical parts. Proper maintenance of the stainless steel components ensures that the machine continues to operate efficiently and reliably, supporting high-quality pharmaceutical production.

Yes, the injectable liquid filling and stoppering machine is designed to handle different types of stoppers, providing versatility for various pharmaceutical products. The machine's stoppering unit can accommodate both full and half stoppering operations, allowing for flexibility in product packaging. The vibratory bowl feeder can be adjusted to align and feed different sizes and shapes of stoppers, ensuring they are correctly positioned for the pick and place system. The stopper holding plate, equipped with a vacuum system, securely holds and places the stoppers into the vials, regardless of their type. This capability ensures that the machine can be used for a wide range of products, from standard rubber stoppers to specialized ones used for specific applications. By handling different types of stoppers, the machine enhances its versatility and usefulness in pharmaceutical manufacturing.

The injectable liquid filling and stoppering machine is equipped with several safety features to ensure safe and reliable operation. The "No vial, no filling" system prevents liquid from being dispensed if a vial is not properly positioned, reducing the risk of spills and contamination. The machine is also equipped with emergency stop buttons that allow operators to quickly halt operation in case of an emergency. The PLC control system enables real-time monitoring and adjustments, ensuring that the machine operates within safe parameters. Additionally, the machine is designed with protective covers and guards to prevent accidental contact with moving parts. Regular maintenance and inspections help ensure that all safety features are functioning correctly, contributing to a safe working environment.

Conclusion

In summary, the injectable liquid filling and stoppering machine offers numerous advantages for pharmaceutical manufacturing, including high precision, efficiency, and versatility. The machine's advanced servo motor and PLC control systems ensure accurate and reliable operation, while the "No vial, no filling" system and other safety features enhance its safety and efficiency.

The machine's ability to handle different vial sizes and stopper types makes it suitable for a wide range of products, from vaccines to antibiotics and biologics. Regular maintenance of the stainless steel components and adherence to manufacturer guidelines ensure the machine's durability and performance. Overall, the injectable liquid filling and stoppering machine is an essential tool for modern pharmaceutical manufacturing, supporting the production of high-quality and safe injectable products.

Future trends in liquid filling technology

As technology continues to advance, future trends in liquid filling technology are expected to focus on further enhancing precision, efficiency, and automation. Innovations such as the integration of artificial intelligence and machine learning could enable machines to self-optimize and adapt to different production conditions, improving overall efficiency and reducing downtime.

The development of more advanced sensors and control systems will enhance real-time monitoring and predictive maintenance capabilities, ensuring that machines operate at peak performance. Additionally, the use of sustainable materials and energy-efficient designs will contribute to more environmentally friendly manufacturing processes. By staying ahead of these trends, pharmaceutical manufacturers can continue to improve their production capabilities and maintain high standards of quality and safety.