HMPL Sterile Unveils Fully Automatic Robotic Uni-Dose Nasal Spray Filling, Stoppering & Assembly Machine

Harikrushna Machines Pvt. Ltd. (HMPL Sterile), the Indian packaging and processing machinery manufacturer with more than 13,000 machines installed in over 67 countries, today announced the unveiling of its Fully Automatic Robotic Uni-Dose Nasal Spray Filling, Stoppering & Assembly Machine. Built by the company's HMPL Sterile division as its second robotic sterile filling system, the machine takes single-dose nasal spray products from empty vials to locked, finished units in one continuous automated flow.

The launch responds to a clear shift in the market. Single-dose nasal sprays are increasingly chosen for emergency medicines, hospital use, paediatric care and vaccine programmes, because each unit delivers one pre-measured dose and is discarded after use. That format removes the in-use contamination risks and dose variability of reused multi-dose bottles, but it places far greater demands on the manufacturing line: when every unit is a patient's entire dose, every unit has to be right.

One Machine from Vial Feeding to Sorted Output

The Robotic Uni-dose Nasal Spray Filling, Stoppering & Assembly Machine integrates 13 process stages into a single system with an output of up to 200 units per minute:

* Vial feeding and vial cleaning
* Liquid filling with 100% check-weighing
* Rubber stopper feeding and vial stoppering
* Visual inspection and automatic rejection of faulty units
* Vial placing and pressing in holder
* Nasal adapter assembly
* Vial holder placement and holder locking
* Sorted collection of good and rejected units

Robotic arms handle key operations including filling, stoppering and assembly, which keeps manual handling to a minimum across the line. By consolidating tasks that are often spread across several machines and manual transfer steps, the system reduces the number of points at which a unit can be touched, delayed or mixed up.

Every Dose Verified, Not Sampled

A central feature of the system is 100% check-weighing. Instead of relying on periodic sampling, every filled unit is weighed during the liquid-filling stage and verified against its tolerance before it moves to the next stage. For a product where each vial is the complete dose, the approach turns dose verification into a per-unit measurement, and the resulting data also gives operators an early view of any drift in fill performance.

An integrated automatic visual inspection station then examines every filled and stoppered vial. Units that fail are rejected automatically and are collected separately from good output, so non-conforming product does not travel forward into the assembly stages.

Designed Around Contamination Control

Human presence is the largest single contamination source in aseptic processing, and regulatory expectations, including the revised EU GMP Annex 1 for sterile manufacturing, place strong emphasis on contamination control strategies and on minimising direct human intervention in critical operations. The robotic architecture of the new machine is designed with that direction in mind: robotic handling of critical steps, automatic reject handling, and a single integrated flow in place of multiple hand-offs.

The machine is intended to operate within a customer's aseptic environment, and its exact configuration is agreed on a project basis.

What It Means for Manufacturers

HMPL expects the machine to be of particular interest to pharmaceutical manufacturers launching or scaling single-dose nasal products, contract development and manufacturing organisations serving multiple clients, and companies planning nasal vaccine or biologic programmes.

Key benefits include:

* Consistent dosing: every unit is check-weighed rather than sampled
* Lower contamination exposure: robotic handling and minimal manual contact across filling and assembly
* Built-in quality control: automatic inspection and rejection of faulty units
* Operational efficiency: filling, stoppering, adapter assembly and holder locking in one continuous process, reducing production time and labour dependence
* Clean output management: automatic sorting of good and rejected units

Availability

The Fully Automatic Robotic Uni-Dose Nasal Spray Filling, Stoppering & Assembly Machine is available to order from HMPL. Technical specifications, process details and a product video are available on our company's website. Prospective customers can request a quote or discuss configuration, fill volumes and component formats with HMPL's engineering team.

Full product details: https://tinyurl.com/2z29jh3v

Watch the video: https://www.youtube.com/watch?v=2cPtjcVRvwM

Harikrushna Machines Pvt. Ltd.
Plot No. 513, Phase IV,
G. I. D. C., Vatva, Ahmedabad
382 445, Gujarat, India

Harikrushna Machines Pvt. Ltd. (HMPL Sterile) is a leading manufacturer of processing and packaging machinery for the pharmaceutical industry, based in Ahmedabad, Gujarat, India. With over 25+ years of industry experience and 13,000+ installations across 67 countries, the company is known for delivering ISO 9001:2015 and CE-certified machinery built to USFDA and EU-GMP standards. HMPL Sterile offers tailored solutions across sterile and non-sterile liquid, syrup, and suspension manufacturing, supported by a strong after-sales service network.

This release was published on openPR.