automatic cartridge filler
Fully automatic insulin cartridge filling machine, aseptic filling solution tailored for pre-filled insulin production
In the field of biopharmaceuticals, the filling accuracy and aseptic assurance of insulin products are directly related to the life safety of patients. The Automatic Cartridge Filler is designed specifically for 1-5ml ready-to-use (RTU) insulin cartridges, integrating high-precision filling technology (±0.01ml) and Class A aseptic isolation systems, solving the core contradiction between efficient production and flexible conversion of small batches for pharmaceutical companies. It is the ultimate solution for fully automatic aseptic filling that complies with cGMP standards.
Automatic Cartridge Filler
High-precision filling
plunger pump + servo drive system ensures 1-5ml insulin filling accuracy of ±0.5ml
Sterility assurance system
equipped with Class A isolation barrier (ISO 5 cleanliness) and 100% online weighing monitoring
Ready-to-use packaging compatible
RTU cartridge bottle platform (supports 1.5/3/5ml specifications)
Flexible production architecture
complete specification switching within 10 minutes, supporting clinical batches as small as 50
Key Advantages for Insulin & Cartridge Packaging
Specially designed vacuum chamber removes headspace air before rubber stopper insertion, preventing air bubble formation and protecting sensitive insulin formulations from oxidation.
Driven by advanced servo systems and high-purity ceramic/rotary piston pumps, ensuring strict volume consistency for low-dose 1.5mL / 3mL / 5mL cartridges.
Fully automated handling under Grade A Laminar Air Flow (LAF) / Isolator-including tub de-nesting, filling, stoppering, and re-nesting-without human intervention.
Smooth starwheel transfer and soft-touch contact components eliminate friction and static electricity, protecting glass cartridges from scratching or breakage.
Technical specifications
| Parameter | Specification |
| Applicable Containers | 1.5 mL / 3 mL / 5 mL RTU Cartridges (Insulin / Dental) |
| Dosing Volume Range | 0.5 mL – 5 mL (Customizable) |
| Filling Accuracy | ≤±1% (Servo-driven Ceramic Pump) |
| Production Speed | 1,200 – 6,000 cartridges/hour (Depending on configuration) |
| Stoppering Rate | ≥ 99.9% (Vacuum Stoppering System) |
| Aseptic Barrier | Class 100 / ISO 5 (LAF Hood / C-RABS / Isolator) |
| Compliance Standards | cGMP, EU-GMP Annex 1, CE, 21 CFR Part 11 |
Application
Automatic Cartridge Filler product full process solution
1
RTU Cartridge Unpacking
2
Nitrogen replacement
3
Precision filling
4
Plug insertion
5
Visual plug inspection
6
100% weight rejection
Automatic Cartridge Filling Adaptation Products
Rapid-acting/long-acting insulin analogs
GLP-1 receptor agonists (such as liraglutide)
Insulin suspension
Service Support
Automatic Cartridge Filling machine
Worry-free warranty
2-year warranty on core components
Quick response
24/7 global technical support, 48-hour on-site support for failures
Customized training
Provide GMP simulation filling practical training courses
FAQ
Q: What is an automatic cartridge filling machine used for in the pharmaceutical industry?
A: An automatic cartridge filling machine is engineered to fill liquid medications into glass or plastic cartridges (typically 1.5ml, 3ml, or 5ml) and seal them with rubber stoppers. It is widely used in the production of insulin, growth hormones, local dental anesthetics, and biotech peptides, ensuring sterile, high-precision dosing for pen-injector devices.
Q: How does the machine achieve bubble-free filling for insulin cartridges?
A: ALWELL cartridge filling equipment utilizes an advanced vacuum filling and vacuum stoppering mechanism. By evacuating air from the cartridge barrel prior to stopper placement, it completely removes headspace air bubbles, ensuring formulation stability and precise dosing accuracy for insulin pen injection systems.
Q: Is the machine compatible with Ready-to-Use (RTU) nest/tub cartridge packaging?
A: Yes. The machine is fully optimized for RTU pre-sterilized cartridges packaged in nests and tubs. Under a Grade A aseptic environment, it automatically performs lid peeling, nest lifting, filling, vacuum stoppering, and re-nesting without direct operator contact.
Q: What is the dosing accuracy for small-volume 1.5ml to 5ml cartridges?
A: Equipped with high-precision ceramic piston pumps and micro-stepping servo drives, the ALWELL cartridge filler delivers a dosing accuracy within ±1%. Optional 100% IPC (In-Process Control) dynamic checkweighing ensures zero off-spec cartridges during high-speed runs.
Q: Can this machine be integrated into a full insulin packaging line?
A: Absolutely. ALWELL provides turnkey packaging solutions. This cartridge filling and stoppering unit can seamlessly link with upstream washer/sterilization tunnels and downstream equipment, such as pen assembly machines, labeling systems, and cartoning lines.
Q: Does the machine support online data logging and audit trails for regulatory compliance?
A: Yes. Our PLC intelligent software control is designed to meet FDA 21 CFR Part 11 requirements. It includes multi-level password authorization, recipes management, real-time historical data logging, and complete audit trail capabilities, ensuring all production and batch data is traceably stored and cannot be modified.
Q: Do you offer FAT (Factory Acceptance Test) and SAT (Site Acceptance Test) services?
A: Yes, we offer both! Before shipment, we conduct a rigorous online or on-site FAT at our factory using your actual bottles and liquid samples, providing you with detailed test videos and documentation. Upon delivery, our engineering team is available for on-site SAT, installation, commission, and operator training at your facility.
Q: What is the delivery time and warranty period for an ALWELL filling machine?
A: Since most pharmaceutical filling machines require customization based on your container sizes and liquid properties, the standard lead time ranges from 60 to 90 days. We offer a 12-month comprehensive warranty from the date of installation, backed by lifetime technical support and fast-tracked spare parts delivery.
Q: How can I get a customized quote for my specific pharmaceutical product?
A: You can click our Contact Us button or send an email with your container specifications (vial/syringe drawing), filling volume (ml), target speed (bottles/hour), and drug characteristics (viscosity, foaming, temperature). Our engineering team will design a detailed technical proposal and quote for you within 24 hours!
[Contact an engineer now to get a customized solution]
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