Advanced Aseptic Filling Machines for Efficient Four Barrel Production

Advanced Aseptic Filling Machines for Efficient Four-Barrel Production

Overview

The Four-Barrel Advanced Aseptic Filling Machine is designed for maximum efficiency, precision, and sterility in pharmaceutical, biotech, food, and beverage manufacturing. By leveraging parallelized four-barrel operation, advanced automation, and cutting-edge aseptic technologies, this machine delivers high throughput while ensuring regulatory compliance (cGMP, ISO, GAMP 5).

Key Features

1. Four-Barrel Parallel Processing

• High Throughput: Fill up to 4 products or lines simultaneously, achieving speeds of 1,200–3,600 containers/hour (depending on product type and container size).
• Independent Control: Each barrel equipped with servo motors, pressure sensors, and load cells for precise, individualized filling.
• Modular Design: Easily scalable to add more barrels or integrate with downstream processes (e.g., capping, labeling).

2. Aseptic & Sterility Assurance

• SIP/COP Sterilization: Automated steam-in-place (SIP) and clean-out-of-place (COP) for barrels, hoses, nozzles, and manifolds.
• Isolator Technology: Optional RABS (Restricted Access Barrier Systems) or full isolator enclosures to maintain ISO 5–7 cleanroom environments.
• A-Class Cleanroom Compatibility: Constructed with stainless steel 316L, polished to Ra < 0.4 μm, and validated for low particle generation.

3. Precision Filling Technology

• Weight-Based Accuracy: Integrated load cells with ±0.1% accuracy for consistent fill volumes.
• Nozzle Options: Customizable contact or non-contact nozzles for vials, bottles, syringes, pouches, or flasks.
• Foam & Air Management: Vacuum or nitrogen purging to prevent foaming and oxidation during filling.

4. Flexibility & Versatility

• Multi-Product Handling: Rapid changeover between different products or container types (e.g., glass vials, plastic bottles, prefilled syringes).
• Fill Volume Range: 0.5–500 ml per container, adjustable via HMI (Human-Machine Interface).
• Viscosity Handling: Suitable for low-viscosity (water-like) to high-viscosity (syrups, creams) products.

5. Automation & Integration

• PLC & HMI Controls: Touchscreen interface for recipe storage, real-time monitoring, and remote troubleshooting.
• Robotic Integration: Compatible with pick-and-place robots for automated container loading/unloading.
• Data Logging: Ethernet/IP connectivity for traceability, batch reporting, and compliance with 21 CFR Part 11.

6. Safety & Compliance

• Locked Seals: Automated clamp closures and pressure sensors to ensure leak-proof operations.
• Particle Detection: Inline laser or vision systems to reject contaminated containers.
• Validation Pack: IQ/OQ/PQ documentation, calibration certificates, and performance protocols included.

Optional Enhancements

• Stopper/Cap Placement: Automated crimping, screw capping, or stopper insertion modules.
• Labeling Systems: Inline printers/applicators for expiration dates, lot numbers, or barcodes.
• Nitrogen Flushing: Overhead or nozzle-based purging to preserve product integrity post-fill.
• Weight Checking: Inline checkweighers for 100% weight verification.
• Lyophilization Support: Compatible with freeze-drying cycles for sensitive biologics.

Applications

• Pharmaceuticals: Sterile injectables, ophthalmic solutions, vaccines, and oral liquids.
• Biotech: Cell cultures, protein solutions, and gene therapy vectors.
• Food & Beverage: Juices, dairy products, sauces, and ready-to-eat meals in aseptic pouches.
• Chemicals: Specialty chemicals requiring aseptic handling (e.g., cosmetics, industrial fluids).

Technical Specifications

• Filling Speed: Up to 3,600 containers/hour (quadruple barrel output).
• Fill Accuracy: ±0.1–0.3% (adjustable via HMI).
• Materials: Stainless steel 316L, silicone gaskets, and certified cleanroom polymers.
• Power: 220V/380V/480V (customizable), 15–25 kW.
• Footprint: Compact design (e.g., 4m x 3m x 3m) with modular expansion options.
• Environment: Designed for Class A–D cleanrooms or ISO 5–8 environments.

Benefits

1. Unmatched Efficiency: Four-barrel design reduces cycle time and increases output without compromising sterility.
2. Precision & Reliability: Weight-based filling and advanced nozzles ensure consistent quality.
3. Compliance: Full traceability, validation packages, and cGMP-compliant design.
4. Low Risk: SIP/COP sterilization and isolator options minimize cross-contamination.
5. ROI: High throughput and reduced labor costs lead to rapid return on investment.

Why Choose This Equipment?

Engineered for speed, precision, and sterility, this four-barrel aseptic filler combines advanced automation with robust quality control to meet the demands of high-volume production while ensuring patient safety and product integrity. Perfect for manufacturers requiring scalable, reliable, and compliant aseptic filling solutions.

Ready to optimize your aseptic filling line? Contact us for a customized quote, workflow analysis, or virtual demo!

Immediate Order:

Website: https://www.glzon.com/product/drumfillingmachines-en.html

Alibaba: https://www.alibaba.com/product-detail/High-Speed-Drum-Filling-Machine-Automatic_1601405682760.html?spm=a2747.product_manager.0.0.515e2c3cjNCu3K

China Manufacturing Co Ltd.: https://fillingmachinecn.en.made-in-china.com