Injectable vial dry powder filling machine with online weighing system

In the highly regulated pharmaceutical industry, precision and sterility are paramount. N.K. INDUSTRIES proudly presents its Automatic Injectable Dry Powder Filling Machine with 100% Checkweigher, a state-of-the-art solution designed to meet these critical demands. This innovative system ensures exact dosage accuracy for every single vial, significantly enhancing product quality, reducing wastage, and maintaining the highest standards of cGMP compliance for injectable dry powder formulations.

N.K Industries with severing the customer a latest technology has developed the new innovative solution for powder filling which is injectable vial dry powder filling machine with 100% online weighing system. In this new technology of machine , there are 2 nos of weighing module installed on first star wheel in filling section where 1st weighing module will measure the empty bottle weight and 2nd weighing module will measure the gross weight (i.e. Total weight of bottle including the filled volume). Human machine interface will display the net weight, gross weight as well as empty weight. If the dosage is not meeting to the accepted criteria of weight tolerance limit then it will be rejected.

The most significant feature of the machine is auto rejection system where container with wrong dosage get rejected and equipped with prominent feature known as No Vial – No Fill system.

What are injectable dry powder filling machine with checkweigher ?

This is a sophisticated automated system specifically engineered for filling sterile dry powder into vials, integrated with an in-line 100% checkweigher. Unlike standard filling machines, this model incorporates a dedicated weighing module that meticulously measures the weight of every single vial before and after filling. This real-time, comprehensive weight verification ensures that each product consistently meets the specified dosage, making it indispensable for high-value and sensitive pharmaceutical products where even minor weight deviations are unacceptable.

Working Principle

The operation of the Automatic Injectable Dry Powder Filling Machine with 100% Checkweigher is a seamless, multi-stage process:

Vial Infeed & Preparation: Vials are fed from an infeed turntable onto a conveyor belt, which transports them precisely through the machine.
Empty Vial Weighing: Each empty vial first passes through a first weighing module where its tare weight is accurately recorded. This data is critical for precise net weight calculation.
Powder Dosing: The sterilized powder, agitated within a hopper to maintain consistent bulk density, is precisely drawn by a vacuum-pressure based dosing system into ports of a rotating powder wheel. As the wheel indexes, the exact pre-determined volume of powder is dispensed into each vial.
Gross Vial Weighing: Immediately after filling, each vial proceeds to a second weighing module where its gross weight (vial + powder) is measured in real-time.
100% Checkweighing & Rejection: The machine's intelligent control system compares the net weight (Gross Weight - Empty Vial Weight) against the programmed target weight and permissible tolerance. Any vial falling outside the acceptable range is immediately identified and automatically rejected into a designated rejection bin, ensuring only perfectly dosed products proceed.
Stoppering/Sealing: Compliant vials then move to the stoppering station, where pre-sterilized rubber stoppers are precisely inserted. Depending on the configuration, subsequent crimping or sealing operations may follow.
Outfeed: The filled, weighed, and stoppered vials are then transferred to an outfeed turntable or downstream packaging operations.

Sailent Feature

Compact Footprint Where Different Modules Like Turntables, Filling And Rubber Stoppering / Screw Capping Are Assembled As One Unit With Minimum Space Requirement.
CGMP Design.
Equipped With 2 Nos Of Weighing Module For Empty And Gross Weight
100% Online Weighing System.
Wrong Dosage Vial Get Automatically Rejected.
Completely Electronically Driven.
Highly Precise Powder Dosing System Based On Vacuum -pressure.
Simple, Fast And Repeatable Changeover.
Positive Vial Transport System I.e. Vial Separator Guide Vials Through Module Like Filling, Stoppering Ensuring They Remain Upright During Transport.
Parts Come In Contact With Sterile Powder & Rubber Stoppers Are Of AISI 316L.
Multiple Dosing Through HMI.
“NO VIAL NO FILL” Scheme Eliminates Wastage Of Costly Powder.
Special Delrin Conveyor Belt To Avoid Sticking Of Vial On Conveyor.
All Electronics Are Of CE Certified.
Autonomous Pneumatic Circuit I.e. Vacuum And Pressure Circuit.
Vacuum Filter Of 10 Micron And Air Filter Of 2 Micron.
The Electrical System Of The Equipment Is Being Housed As Per CGMP And CGEP Standards With Adequate Safety
Digital Vacuum And Pressure Switch For Monitoring Vacuum And Air.

Technical Specification

Filling Speed	10 - 30 Vials/minute Based On 5-10ml Vial For Single Dosage (Depending Up On Size/types Of Vial & Powder Density)
Design	Left To Right
Dosage	100 Mg To 1.5 Grams. Single Dose (with Change Parts) 1.5 Grams To 6 Grams. Double, Triple And Four Doses. Fill Range Depending Upon Vial Opening And Bulk Density Of Powder. Under Controlled Level Of Humidity (i.e. 25%)
Dosing Wheel	One
Dosing Port / Wheel	8 Nos
Fill Accuracy	±2% Depending Upon Consistency And Uniformity Of Bulk Density Of Injectable Powder
Product Conveyor	50 Mm (2") Wide Delrin Conveyor
Powder Suction	Through Vacuum
Powder Delivered	Through Air/Nitrogen (Customer To Provide)
Stopper Delivered	Through Vibratory Bowl & Chute
Machine Dimension	2530 (mm) X 1515 (mm) X 2200 (mm)