Aluminium Flip off Cap Sealing Machine

Q: What is the production capacity of the Aluminium Flip Off Cap Sealing Machine?

The machine is available in different configurations: Four Head : Up to 100–120 vials per minute Eight Head : Up to 180–200 vials per minute The Eight Head model is most commonly used for medium to high-volume sterile production.

Q: What vial and cap sizes can the machine handle?

The Aluminium Flip Off Cap Sealing Machine supports: Vial Diameter : 15 mm to 80 mm Vial Height : 20 mm to 180 mm Flip-Off Cap Sizes : 13 mm, 20 mm, and 28 mm (with suitable change parts) It is suitable for both molded and tubular glass vials.

Description

Aluminium Flip off Cap Sealing Machine is a specialized piece of equipment primarily used in the pharmaceutical industry to seal glass vials with aluminium flip-off caps. These machines ensure a secure, tamper-evident, and sterile closure for injectable drugs, dry powders, or other sensitive products. The Aluminium Flip-off Cap Sealing Machine is designed to efficiently seal glass vials with aluminium flip-off caps, which consist of an aluminium shell and a plastic button that can be flipped off to access the vial’s rubber stopper. These machines are critical for maintaining container closure integrity, ensuring sterility, and providing tamper evidence. They are widely used in pharmaceutical, biotech, and veterinary industries for sealing vials containing injectable liquids, sterile powders, or other sensitive compounds.

The Aluminium Flip-off Cap Sealing Machine is an essential tool for pharmaceutical and related industries, offering efficient, reliable, and sterile sealing of glass vials. With various models available to suit different production scales, these machines provide flexibility, safety, and compliance with industry standards. For more details or to request a quote, you can contact supplier Adinath International.

Vial Feeding: Filled and stoppered vials are transferred from a filling machine’s conveyor to the sealing machine’s flat conveyor belt.

Cap Placement: The vibratory bowl orients aluminium flip-off caps and delivers them via a chute. The infeed star wheel positions the vial to pick up a cap.

Sealing: The vial, with the cap in place, moves to the sealing turret, where spring-loaded rollers crimp the aluminium cap securely around the vial neck.

Inspection and Output: Sealed vials are inspected for proper crimping and transferred to the next stage, such as labeling.

Cap Quality Checks: The machine’s performance depends on the quality of the aluminum flip-off caps. Caps must have uniform riveting points, no burrs, and proper fit to avoid issues like wrinkled edges or loose seals.

Maintenance: Regular cleaning and maintenance of the vibratory bowl, conveyor, and sealing rollers are necessary to ensure consistent performance.

If you need details on specific models, pricing, or comparisons with multi-head machines, let me know!

Salient Features of Aluminium Flip off Cap Sealing Machine

Compact GMP model.
Quick and very easy change over and setting from one size of Container to another by a Single Ratchet.
Parts coming in contact with the Container or the Aluminum cap or exposed to atmosphere are made out of stainless steel for long life.
Single motor synchronizes Conveyor, star wheel and Platform Turret and speed can be varied by VFD.
IQ/OQ documentation can be provided.
Machine construction in Stainless Steel Finish
Cap Feeder with Variable Speed System for feeding control of caps. (optional)
Digital counter for counting production output.

“No Bottle – No Cap” system.
“Container Overturn – Machine Stop” mechanism.
Hopper can be completely dismantling for easy cleaning
Various safety features including Clutch system to avoid Bottle Breakage or Jamming
Star Wheel is equipped with safety clutch for automatic stoppage of machine in case of jamming or overloading.
PLC system with Graphical User Interface can be offered.
Inbuilt Laminar Air Flow can be offered for sterile class 100 filling.
Sampling and Rejection system can be provided on demand.

Working Principle of Aluminium Flip off Cap Sealing Machine

The filled bottles moving on conveyor belt and fed into an in feed star wheel by in-feed worm. While moving in feed star wheel, bottles pick up caps one by one from delivery chute. The descending rotary sealing heads hold bottle’s neck with desired pressure. The sealing is done in a programmed roll-on manner, accurate positioned of the caps is done mechanically by means of a rotating unscramble, to direct the caps correctly into the chute, when the chute is filled up the rotating unscramble drive is disengaged, hence, there is no chance to damage of caps. The sealing roller takes place due to rotating sealing head and transfer movement of sealing & threading rollers due to sealing cam. The sealed bottles are discharged by exist star wheel on conveyors.

Technical Specification of Aluminium Flip off Cap Sealing Machine

Model	ACSR-60	ACSR-120	ACSR-200
No. of Capping Heads	Single	Four	Eight
Production Rate	Up to 50 Containers/Minute	Up to 100 Containers/Minute	Up to 200 Containers/Minute
Container Diameter:	24mm to 90mm	24mm to 90mm	24mm to 90mm
Container Height:	50mm to 250mm	50mm to 250mm	50mm to 250mm
Cap Diameter:	20mm, 25mm & 28mm with the help of change parts	20mm, 25mm & 28mm with the help of change parts	20mm, 25mm & 28mm with the help of change parts
Power Specification:	1 H.P.	1 H.P.	2 H.P.
Electrical characteristics	440 Volts, 3 Phase, 50 Hertz, 4 Wire System	440 Volts, 3 Phase, 50 Hertz, 4 Wire System	440 Volts, 3 Phase, 50 Hertz, 4 Wire System
Conveyor Height	800mm to 900mm adjustable	800mm to 900mm adjustable	800mm to 900mm adjustable
Optional Accessories	Safety Cabinet Covering Machine	Safety Cabinet Covering Machine	Safety Cabinet Covering Machine
–	PLC with HMI	PLC with HMI	PLC with HMI
Overall Dimension	1500mm (L) X 850mm (W) X 1800mm (H) approx.	1675 (L) x 1000mm (W) x 1800mm (H) approx.	2000 (L) x 1000mm (W) x 1800mm (H) approx.

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.

Types of Capping and Sealing Machine

Automatic Ropp Screw Capping Machine

Automatic Bottle Screw Capping Machine

Automatic Bottle CRC Capping Machine

Automatic Bottle Lug Capping Machine

Automatic Vial Capping Machine

Automatic Jar Capping Machine

Automatic Linear Bottle Capping Machine

High Speed Vial Cap Sealing Machine

High Speed Bottle Capping Machine

Semi Automatic Bottle Capping Machine

Applications of Capping and Sealing Machine

Advantages of Aluminium Flip off Cap Sealing Machine

Sterility and Safety: Ensures a sterile, tamper-evident seal to protect vial contents.

Efficiency: Increases sealing speed and reduces labor compared to manual methods.

Reliability: Precision technology minimizes cap damage and ensures consistent sealing quality.

Versatility: Adjustable for various vial sizes and cap types, with quick changeover times.

Key Features of Aluminium Flip off Cap Sealing Machine

Construction and Design:
- Compact and Robust: Most models are compact, making them suitable for various production scales, from small to large. They are typically constructed with stainless steel for durability, corrosion resistance, and compliance with Good Manufacturing Practices (cGMP) standards.
- Enclosed Structure: Machines often feature stainless steel cladding or enclosures with safety doors for hygienic operation and easy maintenance.
- Single Motor Synchronization: A single motor often drives the conveyor, star wheels, and platform turret, with speed control via a variable AC frequency drive for flexibility.

Sealing Mechanism:
- Spring-Loaded Sealing Rollers: These rollers ensure uniform, scratch-free, and reliable sealing without damaging the aluminium caps. They accommodate variations in vial neck diameters, providing flexibility.
- Tamper-Evident Closure: The machine applies flip-off caps that break small aluminium bridges when the plastic cap is removed, ensuring tamper evidence.
- Precision Sealing: The sealing head performs threading and sealing with high precision, ensuring a tight fit between the aluminium cap and the vial.

Automation and Speed:
- Variable Output: Machines come in different configurations to match production needs, with speeds ranging from 40 to 400 vials per minute depending on the model and head count.
- Automated Cap Feeding: Caps are fed via a vibratory bowl or chute, automatically oriented for correct placement on the vial. A photo-sensing device can stop the machine if no caps are detected in the chute.
- Conveyor and Star Wheel System: Vials are fed from a filling machine conveyor to an infeed worm and star wheel for precise spacing and positioning under the sealing head.

Safety and Control Features:
- No Vial/No Cap System: Prevents operation if a vial or cap is missing, reducing errors and breakage.
- Clutch System: Incorporated in the infeed worm and star wheel to stop the machine in case of vial jamming or overturning, preventing damage.
- Programmable Logic Control (PLC): Optional PLC with a Human-Machine Interface (HMI) for precise control and monitoring.
- Digital Vial Counter: Tracks the number of sealed vials for production monitoring.

Customization and Flexibility:
- Adjustable Sealing Pressure: Allows for sealing different cap sizes and gauges.
- Interchangeable Parts: Machines support both plain aluminium seals and flip-off seals with common change parts, enabling quick changeovers for different vial sizes.
- Optional Features: Laminar Air Flow for sterile Class 100 environments, IQ/OQ/DQ documentation for validation, and acrylic/stainless steel safety cabinets.

FAQ for Aluminium Flip off Cap Sealing Machine

What is an Aluminium Flip Off Cap Sealing Machine?

The Aluminium Flip Off Cap Sealing Machine is a specialized rotary sealing machine designed to apply and crimp aluminium flip-off caps on glass vials. It is widely used in the pharmaceutical and biotech industries for sealing injectable products such as vaccines, antibiotics, lyophilized powders, and sterile liquids. The machine ensures a secure, hermetic, and tamper-evident seal while maintaining sterility.

What is the production capacity of the Aluminium Flip Off Cap Sealing Machine?

The machine is available in different configurations:

Four Head: Up to 100–120 vials per minute
Eight Head: Up to 180–200 vials per minute

The Eight Head model is most commonly used for medium to high-volume sterile production.

What vial and cap sizes can the machine handle?

The Aluminium Flip Off Cap Sealing Machine supports:

Vial Diameter: 15 mm to 80 mm
Vial Height: 20 mm to 180 mm
Flip-Off Cap Sizes: 13 mm, 20 mm, and 28 mm (with suitable change parts)

It is suitable for both molded and tubular glass vials.

What are the key features of the Aluminium Flip Off Cap Sealing Machine?

Key features include:

Precise and uniform crimping of flip-off aluminum caps
“No Vial – No Cap” and “No Stopper – Machine Stop” safety systems
Spring-loaded sealing heads for consistent sealing pressure
Safety clutch to prevent vial breakage
Stainless Steel (SS 316) contact parts for GMP compliance
Low particle generation during sealing

What are the key benefits and optional features?

Key benefits include reliable tamper-evident sealing, excellent hermetic closure, quick size changeover, easy maintenance, and high sealing accuracy. Optional features include:

PLC with HMI and touchscreen
Laminar Air Flow (LAF) unit for Class 100 environment
Full safety cabinet enclosure
Camera inspection system
IQ/OQ documentation and 21 CFR Part 11 compliance

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