How Can an Ampoule Washing, Sterilizing, Filling and Sealing Integrated Machine Reduce Breakage Rate?

Ampoules are fragile and prone to breakage during washing, transfer, filling, and sealing processes. This directly impacts product yield and production costs. Advanced ampoule washing, sterilizing, filling, and sealing integrated machines significantly reduce breakage rates through process optimization and structural improvements.

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In traditional ampoule production, breakage is most common in three stages: high-speed transfer, filling alignment, and high-temperature sealing. Modern integrated machines address these issues with the following technologies:

1. Flexible Transfer System: Servo-driven precision conveyors minimize vibration and collisions, reducing glass breakage.

2. Independent Clamping Structure: Bottle clamps made of food-grade silicone or stainless-steel cushions ensure secure positioning while reducing mechanical stress.

3. Buffer Transition Design: Buffer stations are added between washing-drying and drying-filling to reduce shock during high-speed transitions.

4. Precision Filling System: Ceramic pumps or servo-driven metering pumps ensure exact needle-to-bottle alignment, preventing neck damage caused by misalignment.

5. Temperature-Controlled Sealing: Flame-sealing with automatic rotation provides uniform heating, avoiding cracks from localized overheating.

6. Online Monitoring & Rejection: High-speed cameras and sensors detect cracks or deformation in real-time, automatically rejecting defective bottles to prevent secondary damage.

With these improvements, advanced integrated machines can achieve breakage rates as low as ≤0.1%, compared to 1–3% in traditional equipment, significantly improving yield and productivity.