SBLFRS Automatic Four/Six Head vial filling with Rubber Stoppering Machine is a compact model used for filling and rubber Stoppering of Injectable liquid into vials.

The incoming dry vial (sterilized) are fed through the Unscrambler and suitably guided on the moving delrin slat conveyor belt at the required speed of the correct placement below filling unit.

The filling unit consists of Filling Head, Syringes & Nozzles which are used for liquid filling. The syringes are made of S.S. 316 construction and both, glass as well as S.S. syringes can be used. A Star Wheel is provided which holds the vial during filling operation. A sensor is provided for ’’No Vial, No Filling’’ operation. Syringes are mounted on eccentric block and driving through bottom main gear box. Volume can be either increased or decreased by increasing or decreasing stroke length of piston as per filling size. Syringes is having non return valve for sucking and delivering situation to avoid volume variation. Liquid will reach to filling nozzles through silicon transparent pipe. Nozzle will be having Up and Down movement with help of cam mechanism and it will come down when vial will be hold by star wheel for filling operation and starts filling when it starts to move up and after completion of filling operation, star wheel delivers four/six vials together on conveyor for rubber Stoppering operation.

Stoppering unit consist of Star wheel, Vibrator unit and Bowl. The sterilized/autoclaved rubber stoppers stored in the vibrator bowl moves vertically to the rubber stopper chute. The vial is hold firmly by star wheel, which will be in continuous rotary motion and vial which is coming from filling unit get in to star wheel and move in rotary direction along with star wheel, during movement it will pick up the rubber stopper from the exit end of the chute and rubber stopper will be pressed by fix single pressing roller, which is spring loaded. Then vial further move on conveyor and collected on out feed star wheel for next sealing operation.

Features

• M.S. Moulded structure duly powder coated to avoid any vibration with adjustable screws to adjust conveyor height as per in feed tunnel.
• Total cGMP model.
• All parts and assemblies coming in contact with liquid and rubber stopper are made of S.S.316 and easily removable for mandatory Autoclaving/Sterilization.
• “NO VIAL, NO FILL” System eliminates wastage of costly liquids.
• All assemblies under top plate are positioned as for easy cleaning or maintenance.
• Double dosing for 100 ML is also possible.
• All driving is through High quality imported Gear motor for better machine performance without vibration or leakage of oil of area floor from gear box.
• Machine speed can be adjusted through A.C. Frequency drive, which is time saving and the machine speed, can be easily synchronized with Unscrambler, scrambler and conveyor.
• Machine is provided with delrin conveyor belt to avoid sticking of vial on conveyor.
• Special clutch devices are provided on star wheel for safety purpose.
• Vibratory bowl for rubber Stoppering unit support to run machine with total claimed speed of machine.
• Imported Gear Motor for Main drive, Unscrambler and scrambler and conveyor.
• A.C. Frequency drives for Main drive, Unscrambler, Scrambler and conveyor.
• Pre and Post gassing unit for Nitrogen or Carbon Dioxide flushing.
• “No Vial, No Filling” System.
• “No Stopper in Chute, Machine Stop System”.
• Acrylic Cabinet with Imported Aluminium Structure for Machine, Unscrambler and Scrambler.

Automatic Injectable Powder Filling with Rubber Stoppering is a compact model used for filling Stoppering of Dry Powder Injectable in to vials.

The incoming dry container sterilized are fed through the Unscrambler and suitably guided on the moving delrin flat conveyor belt at the required speed of the correct placement below powder wheel.

The sterilized powder is stored in powder hopper is agitated by pair of mechanical agitators for maintaining consistency and uniform bulk density. The powder wheel having eight ports rotates at the pre determined speed below the powder hopper with practically no clearance. Powder wheel consist of Piston in each port and behind the powder wheel vacuum plate is provided there is no clearance between powder wheel and vacuum plate due to back spring pressure. Precise volume of powder is sucked in to the port of powder wheel during vacuum according to the piston length different fill size can be achieved. The excess powder is doctored off by a doctor blade. Doctor blades can be adjusted from outside also without removing powder hopper. When powder wheel indexes further and remain in the port due to the vacuum till it reaches just vertically above the container. The time dose of Compressed air (Nitrogen Gas), sterilized low pressure air sequentially flushes out powder from the port of powder wheel in to the container one by one.

The filled container is immediately separated on the conveyor by vial separator and moves further for Stoppering operation. (Different grooves separator can be used which depends on the container diameter or multiple dosing systems).

The sterilized, siliconised, rubber stoppers stored in the vibrator bowl moves to vibratory bowl and stacked vertically in the rubber stopper chute. The container is hold firmly between pair or timing belt to pickup rubber stopper from exit end of the chute. Further the container is passed between two pressing roller for tight fit fixing of rubber stopper.

Salient Features

• M.S. moulded structure duly powder coated to avoid any vibration with adjustable screws to adjust conveyor height as per in feed tunnel.
• Total Table top cGMP model.
• All parts and assemblies coming in contact with powder and rubber stopper are made of S.S.316 and easily removable for mandatory Autoclaving/ Sterilisation.
• “NO VIAL, NO FILL” System eliminates wastage of costly powder.
• Spring loaded Teflon top seal for powder hopper reduces the friction between and top seal and avoid chance of white particle shading during production.
• Doctor blade and wiper blade can be adjusted from outside also without disturbing any production, which saves lot of time, powder wastage and chances of area condition disturbance.
• All assemblies under top plate are positioned as for easy cleaning or maintenance.
• Multiple dosing of Injectable powder or change over of container size and different fill size is possible by just changing the vial separator or size of the piston respectively.
• All driving is through High quality imported Gear motor for better machine performance without vibration or leakage of oil of area floor from gear box.
• Machine speed can be adjusted through A.C. Frequency drive, which is time saving and easy to synchronise Unscrambler and scrambler speed with machine speed.
• Machine is provided with delrin conveyor belt to avoid sticking of vial on conveyor.
• Special clutch devices are provided on vial separator for safety purpose.

Sophisticated modular construction enables individual machines to be linked to form integrated processing lines. For every output range a selection of Machines for Washing, Sterilizing & Depyrogenating, Filling / Dosing and Bunging & Cap sealing is available, customized to suit individual requirements, we design and construct complex production lines for processing Vial.

LIQUID INJECTABLE LINE	POWDER INJECTABLE LINE
Rotary / Linear Vial Washing Machine Dry Heat Sterilizing And Depyrogenating Tunnel Liquid Vial Filling & Rubber Stoppering Machine Vial Aluminium Cap Sealing Machine Pre And Post Inspection Systems Labelling Applicator Packing And Transfer Conveyor System.	Linear / Rotary Vial Washing Machine Dry Heat Sterilizing And Depyrogenating Tunnel Dry Powder Filling & Rubber Stoppering Machine Vial Aluminium Cap Sealing Machine Pre And Post Inspection System Label Applicators Packing And Transfer Conveyor System.
AMPOULE LINE	DRY SYRUP LINE
Multi Jet Washing Dry Heat Sterilizing And Depyrogenating Tunnel Ampoule Filling And Sealing Pre And Post Inspection System Label Applicator Packing And Transfer Conveyor System	Air Jet Washing Auger Type Filing Cap Sealing Visual Inspection System Label Applicator Packing And Transfer Conveyor System

CAPACITY OUTPUT RANGE:

• 60 To 120 VIALS AND AMPOULES PER MIN
• 80 To 150 VIALS AND AMPOULES PER MIN
• 120 To 240 VIALS PER MIN

Water for Injection (WFI) SYSTEM comprises of

• Multicolumn Distillation Plant
• WFI Storage System
• WFI Distribution Loop System
• Pure Steam Generator


The pre-treatment system comprises of:


• Pressure Filters, Activated Carbon Filters
• D.M. Plant or Reverse Osmosis system (with Softner)
• Ultra-Filtration system
• UV Sterilizer
• Storage and Distribution loop system.

To industries where 100% pure Pyrogen - free water-for injection plays role, Multicolumn Distillation Plant is the perfect solution. Available in capacities ranging from 80 - 5000 LPH, the Multicolumn Distilled plant is used for its economy, low maintenance and low operation costs.

Some of the special features of Multicolumn Distillation Plant are:

• Pure Sterile Pyrogen free distilled water conforming to USP standards.
• Compact in design.
• All contact Parts are in SS 316 / SS 316 L.
• Electro polished creviceless inner contact surfaces.
• PLC based system for automated operation.
• Sanitary triclover fittings for quick and easy preventive maintenance.
• Double tube Sheet construction for the first column, where boiler steam is present.
• Synoptic panel board with facility for logging the data can also be given.

Vertical / Horizontal Distilled Water Storage Tank is available in both jacketed and non jacketed design. If WFI is to be stored overnight or for a longer period of time, then it is essential to keep it in hot condition, at around 80 C. Distilled Water Storage Tank with jacketed design, where heating medium is either boiler steam or electrical heaters in the jacket, provides you with an ideal solution.

WFI Storage tank will have the following special features

• The tank is designed to withstand pressure as well as vacuum. Therefore it can be steam sterilized.
• No stagnant points which will promote bacterial growth.
• All surfaces are creviceless and having high degree of finish.
• Insulation with SS welded sheeting and jacket provided on the tank will minimize heat loss.
• All the surfaces coming in contact with WFI are made of SS 316/316L quality.
• Electropolished interiors are provided as optional.
WFI (Water for Injection) Storage Tank are supplied with the following accessories

• Spray Ball for SIP / CIP.
• Temperature Indicator cum Control Arrangement.
• Level Indicator cum Controller.
• 0.2 Micron Vent Filter.
• Pressure Gauge and Safety Valve.
• Diaphragm Valve.
• SS panel.

WFI Distribution Loop System has the following special features:

• Material of construction - SS 316L.
• Internals electro polished to Ra < 0.8.
• Externals Mechanically polished to 180 grit finish.
• Welding technique - Automatic Orbital Welding.
• All interconnections through triclovers.
• All valves are of self draining type.
• All gaskets are of Teflon.
• Dead leg not more than 6d for d < 30mm.
• Dead leg not more than 3d for d >/=30mm.
• Entire installation will be completely drainable.
• Slope of the low point must be 1: 100 minimum.

Following accessories are supplied as a part of the loop system

• WFI circulation pump.
• Saunders diaphragm valves.
• Temperature Indicator cum Controller.
• Flow Indicator cum Totalizer.
• Conductivity Indicator cum Controller.
• Sanitary Diverting Valve.
• Back Pressure Valve.
• Panel board with Data Logger, printer and alarm system.

Pure Steam Generator for the Pharmaceutical and Biotech Industries is the most reliable technology for producing pure, Pyrogen free sterile Steam. Pure Steam is defined as uncondensed Water for Injection and meets the Indian, British and the United States Pharmacopoeia.

The use of Pure Steam Generator will have the following advantages:

• Pure Pyrogen free sterile steam is available for Sterilization.
• Pure Steam when condensed will give WFI quality water. This is very advantageous, as steam which gets condensed after sterilization will not be a source of contamination.
• It is ideal in sterilization of Pipelines, Tanks, Fermentors etc.
• Suitable for humidification of sterile areas where pure steam is required.

Pure Steam Generators are available in output capacities ranging from 25kg/hr to 2000kg/hr.

Special features of Pure Steam Generators are :

• Pure Sterile Pyrogen free Pure Steam conforming to USP standards.
• Compact in design.
• All contact Parts are in SS 316 / SS 316 L.
• Electro polished creviceless inner contact surfaces.
• Sanitary triclover fittings for quick and easy preventive maintenance
• Double Tube Sheet construction for the first column, where boiler steam is present.
• Synoptic panel board with facility for logging the data can also be given.
• Automatic operation of the system in accordance with Pure Steam demand.