The Ampoule Filling Line is an advanced and fully integrated system designed for the production of 1-20ml ampoule injections. This comprehensive line includes a Vertical Ultrasonic Bottle Washing Machine, a Circulating Hot Air Tunnel Sterilization Oven, and a Vertical Fill-Seal Machine, which together provide a complete solution for the efficient and precise production of ampoules. The system is divided into three main areas: the washing area, the drying and sterilization area, and the filling and sealing area. Each of these sections can function independently, allowing flexibility in production processes.
This Ampoule Filling Line is particularly suited for small-volume injection production and incorporates over 20 distinct procedures. These include critical processes such as water spraying, ultrasonic washing, bottle handling using a manipulator, bottle turnover, and swashing of both the inner and outer surfaces. Additional steps include blowing to ensure complete cleanliness, preheating, drying, sterilization, cooling, optional nitrogen filling, precise liquid filling, further nitrogen protection, and final preheating and sealing of the ampoules. This extensive range of procedures ensures that the production process meets the highest standards of quality and safety.
Features
The Ampoule Wash-Dry-Fill-Seal Production Line integrates washing, sterilization, filling, and sealing processes to ensure the complete and sterile production of small-volume ampoule injections. It boasts a modern, advanced design that emphasizes a well-structured, highly automated, and reliable operation. The high degree of mechanical and electrical integration ensures that all components work together seamlessly to achieve maximum efficiency and production output.
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- Material Composition: All components that come into contact with the liquid are constructed from high-grade AISI316L stainless steel, known for its corrosion resistance and suitability for pharmaceutical use. The other structural parts are made from AISI304 stainless steel, ensuring both durability and a high level of hygiene. These materials guarantee that the ampoule production process remains free of contamination, both for the liquid and the environment.
- Component Overview: The complete production line consists of three main units: the Vertical Ultrasonic Washing Machine, the Drying and Sterilization Oven, and the Ampoule Fill-Seal Machine. These machines work in coordination, featuring interaction and stepless speed regulation. This allows for precise control of each production stage and ensures that the process meets all required technical and regulatory standards.
- High Production Efficiency: The ampoule filling line is designed for high-speed production, ensuring that the manufacturing process is both fast and efficient. The system minimizes the risk of operational errors, such as impact, incorrect actions, bottle squeezing, or breakage. This results in a higher qualification rate for ampoules, significantly reducing waste and increasing output.
- Safety Features: Operator and machine safety is a priority. The ampoule filling line is equipped with various safety devices to protect both the machinery and personnel involved in the production process. These safety measures ensure that operations can be carried out smoothly without risking damage to equipment or compromising worker safety.
- Validation and Control: Key parts of the system are equipped with validation ports, allowing for routine checks and ensuring that all components are functioning optimally. The entire line is controlled by a PLC system, offering a touch screen interface for ease of operation. The system’s programmable nature allows for automated production sequences, making it highly adaptable to different production requirements.
- Buffer Devices and Continuous Operation: To ensure stable and reliable operation, buffer devices are strategically installed between the three primary units of the production line. These devices help maintain a continuous flow, reducing downtime and ensuring consistent performance.
- Efficiency Features: The ampoule filling line incorporates several intelligent functions to improve operational efficiency. For example, the system has a “no bottle, no filling” feature, which prevents the wastage of materials when bottles are not present. The inclusion of a centralized oil supply system simplifies maintenance by allowing easy lubrication of key components without interrupting production.
