Industrial-grade tube filling line with 150 pcs/min throughput. Handles tubes up to 60mm diameter for high-volume cosmetics and pharmaceutical production runs.
The YG-200 is YohoAI's high-output tube filling and sealing line for mass production environments. With a maximum throughput of 150 pcs/min and compatibility with tube diameters up to 60mm, it handles the largest tubes used in pharmaceutical ointments and industrial sealants. The machine integrates tube loading, filling, sealing, coding, and output in a single continuous line with automatic rejection of under-filled tubes. Changeover between standard tube sizes takes under 45 minutes. The YG-200 is the recommended choice for manufacturers running batches of 10,000+ units.
Verified factory data - not marketing estimates
Servo-driven continuous motion system delivers 150 pcs/min at rated speed. Automatic tube feeder with buffer magazine handles 500+ tube capacity, reducing manual feeding labor.
In-line weight check and visual inspection automatically reject under-filled or improperly sealed tubes. Reject rate display on HMI with batch logging.
Integrated tube loading, filling, sealing, batch coding, and output in one continuous motion. No start-stop cycles, maximizing OEE (Overall Equipment Effectiveness).
Filling accuracy of +/-0.5% verified by in-process weight control. Optional nitrogen flushing for oxygen-sensitive formulations. 21 CFR Part 11 compliant data logging optional.
Diameter changeover within 13-60mm in under 45 minutes using the standard changeover kit. No special tools needed. Recipe storage on HMI for up to 200 product formats.
Optional PLC remote access for remote diagnostics and software updates. Production data exportable via USB or Ethernet. OEE dashboard on HMI shows real-time efficiency metrics.
Our team responds within 2 hours with CIF/CFR/FOB pricing and delivery timeline.
The YG-200 accommodates tube diameters from 13mm to 60mm in a single configuration. This covers the full range of standard cosmetic and pharmaceutical tubes including large-diameter tubes used for ointments and industrial products. Diameter changeover uses the included changeover kit with no additional parts.
The rated speed of 150 pcs/min is achievable in sustained production with experienced operators and consistent product viscosity. Real-world OEE for most facilities is 75-85% of rated speed, yielding 110-130 pcs/min in sustained 8-hour shifts. The YG-200's continuous motion design maintains higher OEE than intermittent-motion alternatives.
The YG-200 uses a dual-check system: an in-line weight sensor checks every filled tube, and a vision camera inspects seal quality. Under-filled or poorly sealed tubes are diverted to a dedicated reject bin. The HMI logs every reject with timestamp and reason code for traceability and process improvement.
The YG-200 requires a 380V/50Hz 3-phase power supply rated at minimum 30A. Single-phase conversion is not available. An on-site electrical inspection is recommended before installation. The machine includes a built-in isolation transformer and surge protection.
The YG-200 is quoted per project depending on accessories (nitrogen flushing, remote monitoring, 21 CFR Part 11 package, custom voltage). Standard delivery is 45-60 working days. Installation and commissioning take 3-5 days on-site. IQ/OQ/PQ documentation packages are available as an add-on.
Yes. For abrasive or corrosive formulations (certain pharmaceutical actives, acid-based cosmetics), YohoAI offers hardened pump materials (ceramic, carbide) and product contact surface upgrades to 316L stainless steel. Please specify product details at inquiry so we can recommend the appropriate material configuration.
Every YG-200 includes: 2-3 days on-site operator and maintenance training, bilingual (English/Chinese) user manual, electrical schematics, PLC program backup on USB, and spare parts list. Optional IQ/OQ/PQ validation protocols are available for pharmaceutical GMP compliance.
For pharmaceutical manufacturers: 18-24 months based on reduced labor costs (1 operator vs. 3 for manual filling) and lower reject rates. For contract manufacturers: 12-18 months based on increased throughput capacity enabling new high-volume client contracts. The continuous motion design significantly reduces per-unit labor costs at scale.
The YG-200 high-speed tube filling line requires a dedicated production area with controlled humidity (below 60% RH) and temperature (18-25 deg C). Install on a level concrete foundation with anchor bolts and connect 380V three-phase power, 0.5-0.7 MPa clean compressed air, and a drainage line for the cooling system. The ultrasonic sealing unit requires a separate 220V connection and grounding.
Daily operations should start with a 10-minute warm-up of the hot air sealing system to reach stable temperature. Check the ultrasonic generator frequency (20 kHz standard) and verify the fill volume calibration with 10 sample tubes. After each production run, purge the filling system with cleaning solvent if switching products, and wipe down the sealing area with isopropyl alcohol.
Weekly maintenance includes inspecting the ultrasonic horn tip for wear, checking the conveyor drive belt tension, and cleaning the photoelectric registration sensors. Monthly tasks should cover the servo motor couplings, the filling valve O-ring replacement schedule, and the air dryer desiccant inspection.
High-speed automatic filler at 150 pcs/min
The YG-200 is the high-speed automatic tube filler, rated at 150 pcs/min for continuous high-volume production. Its servo-driven volumetric piston delivers 10-250 ml at +/-0.5% accuracy - twice the precision of the pneumatically assisted YG-120 - verified by in-line checkweighing. A 20-station rotary magazine and photoelectric registration eye align printed artwork to +/-0.5 mm before dosing. Sealing uses hot-air for aluminium and ultrasonic for laminate and plastic tubes, performed by a module swapped in under 20 minutes. The colour HMI stores 200 recipes and auto-sets fill, speed, and seal parameters. Product-contact parts are 304 stainless steel (316L optional) with Ra < 0.8 um and CIP-ready tool-free disassembly. The 3.5 x 1.2 x 2.1 m frame draws 8.5 kW from a 380V three-phase supply and weighs 1,800 kg for stable high-speed operation.
Maximising throughput for single high-volume SKUs
The YG-200 maximises throughput for single high-volume SKUs. At 150 pcs/min with +/-0.5% servo accuracy it outperforms the 60 pcs/min YG-120 and suits brands filling one or two products continuously rather than many changeovers. The multi-format Automatic line matches top speed but adds hot-air plus ultrasonic sealing and a faster 10-minute changeover for plants running mixed tube types; the YG-200's 20-minute changeover favours stability over flexibility. Footprint and power are larger - 3.5 m frame, 8.5 kW versus 2.2 m, 6.5 kW - and price runs 65-90k USD against 45-65k for the YG-120. For most high-volume manufacturers the YG-200's labor saving per unit (up to 40% versus manual lines) justifies the premium within the first year of operation.
Disciplined upkeep protects high-speed uptime
Running at 150 pcs/min, the YG-200 needs disciplined maintenance to protect uptime. Daily: clean the sealing head, check the pneumatic lubricator and air quality, and run five test tubes after changeover. Weekly: CIP-rinse contact surfaces, inspect tube-holder and seal-jaw wear from high cycling, and verify registration. Monthly: replace sealing plates every 3-6 months by volume, check timing belts, servo couplings, and the indexer cam, then recalibrate dosing. Annually: inspect electrical-cabinet thermals, vibration, and back up HMI recipes. YohoAI's high-speed spare kit - sealing jaws, pistons, O-rings, belts - ships from Shanghai within 48 hours. With the optional annual service contract, planned downtime typically stays below 3% even on three-shift operation, protecting the line's per-unit economics.
130 pcs/min across two 24/7 campaigns
A global oral-care manufacturer installed a YG-200 to fill a 100 ml laminate-tube gel at 130 pcs/min with +/-0.5% accuracy across two 24/7 production campaigns. Ultrasonic sealing gave hermetic, uniform joints that survived the client's drop and leak tests, while servo dosing held net weight within tight regulatory limits and cut overweight giveaway by 0.4 g per tube - a saving that compounds into six figures annually on resin and product. Stored recipes allowed a rapid switch to a 75 ml variant during promotional periods with under 20 minutes of changeover. After a year the line sustained 94% OEE and zero recall-related deviations, leading the manufacturer to standardise the YG-200 across two further regional plants for identical process transfer.
Same documented quality framework as the range
Despite its speed focus, the YG-200 supports the same documented quality framework as the rest of the range. Product-contact parts are 304 stainless steel with Ra < 0.8 um and tool-free CIP disassembly, with 316L available for pharmaceutical tiers. The HMI enforces recipe limits and exports batch records - fill volume, speed, counts - for traceability, and optional 21 CFR Part 11 logging meets electronic-record rules. YohoAI offers an IQ/OQ/PQ protocol package and a commissioning calibration certificate, while in-line checkweighing supplies statistical fill-weight data for capability (Cpk) studies. The sealed, open-frame design eases cleaning validation, letting a single high-speed YG-200 serve cosmetic, food, and pharmaceutical contract work under proper change control without compromising its throughput advantage.
