The pharmaceutical industry demands the highest standards of quality as defined by design, materials, workmanship, GMP, accuracy, usability, security and reliability. Since these same qualities have been the guiding principles since All-Fill was founded in 1969, it is no coincidence that this important sector accounts for an increasingly significant proportion of All-Fill's total production of filling equipment.
All-Fill is able to meet the widest range of customer requirements, from individual filling machines to complete turn-key lines, from fine fluffy sticky powders through to free-flowing granules, all with the option of fully integrated weight control systems. All-Fill support includes a full validation documentation package, with protocols and experienced personnel to assist with installation and operation qualifications for the filling machinery.
Floor-standing pedestal filling machines and bench-top filling machine models are available, in volumetric and gravimetric forms, with all 316L stainless steel contact parts, no tools strip-down for cleaning and 304 stainless steel externals. All filling machines feature PLC control via monochrome or colour touch-screen panel. Filling heads are supplied direct to end-users and machine builders for integration into vertical form-fill-and-seal, sachet and cartonning equipment. They also form the basis of our automatic in-line and high-speed rotary filling systems.
Supplied as standard with a lift mechanism for neck-entry dust-free filling of fine powders and vibration for settling of granular products. Conveyor bed and system frame GMP designed for ease of cleaning. The photograph on the left below shows a Series 100 in-line machine filling dry suspension antibiotics, 20g to 60g, into narrow-neck glass bottles at up to 30 per minute, with neck location for precise neck-entry lift. The photograph on the right below shows an integrated unscrambling filling and stoppering system in fully sealed glove-box enclosure for precise gravimetric filling of biological analysis samples into vials and small bottles.
Twin head systems are available for doubling output volumetrically. These systems can also be configured with weigh-cells beneath the second head for volumetric bulk fill with gravimetric top-up, or with intermediate weighing for higher outputs.
Bespoke and multi-head solutions are available, custom-designed to suit user requirements
Separate dosing of the active product and carrier provide the opportunity to reduce batch validation costs dramatically by scaling down the process plant required to produce the active ingredients.
Pharmaceutical powders with different characteristics require different engineering solutions. All-Fill have the widest range of high-speed high accuracy rotary macro-dosing equipment available.
For fine, sticky, dusty powders, one to four heads using direct neck-entry filling, with optional tare-and-gross weighing and nett weigh calculation for reject.
Continuous Motion Rotary, Intermittent Dosing
With servo drive to the auger, particularly suitable for high speed filling of smaller doses (1g to 5g) of sticky, non-free flowing powders, dosing intermittently into transfer funnels with transfer assist.
Continuous Motion Rotary, Continuous Dosing
For highest speed, continuous filling with a knife-edge plate dividing the continuous powder flow equally into the transfer funnels. Particularly suitable for larger doses, 10g to 100g. Seals between the filling nozzle (auger/funnel) and knife-edge plate keep bottles, machine and environment dust-free.
100% Nett Weight Validation
Floor-mounted high-resolution digital balances integrated within the rotary filler base frame, one upstream/one downstream of the filling/transfer turret, provide 100% nett weight validation. Static tare and gross weighing provides far higher accuracy than could be achieved with traditional dynamic checkweighers. Full integration guarantees mechanical registration, with faster response times, reduced line length and single panel set-up. The exit starwheel reject system operates in “positive accept” mode, diverting under/overweight bottles to a separate reject lane, with reject verification.
All-Fill are able to provide their pharmaceutical clients with a complete documentation package to facilitate pre-production validation and experienced support to assist with on-site validation.
The documentation package includes full process description, software ladder diagram, installation and maintenance instructions, mechanical and electrical drawings, pre-delivery testing protocols and installation/operation qualification protocols.
All-Fill offer their clients a single-source service for all items within the packaging line. Equipment is selected from manufacturers with specialist expertise, following detailed discussions with the end-user to establish current and future objectives and agree a detailed specification. Items such as bottle cleaners, bulk feed systems, metal detectors, check weighers, cappers and labellers can be integrated with All-Fill conveyoring and loading/buffer units to provide a professional turn-key solution precisely tailored to meet the client’s needs.