Aseptic Liquid Filling Machine is a specialized piece of equipment designed to fill containers with liquid products in a sterile environment, ensuring no contamination by pathogens or microorganisms. It is widely used in industries like pharmaceuticals, food and beverage, and cosmetics for packaging products such as vaccines, injectable drugs, dairy products, juices, and sauces. The machine operates within a closed, controlled system to maintain sterility throughout the process. The process begins with thorough sterilization of all components, including containers and filling equipment, using methods like steam, hydrogen peroxide, or electron-beam technology. Containers are typically moved through the machine via a conveyor system, where they are filled with precise volumes of liquid using nozzles or peristaltic pumps, ensuring high accuracy. The filling occurs in a sterile zone, often under isolators or restricted access barrier systems, with unidirectional airflow to prevent contamination. After filling, containers are sealed with caps, stoppers, or heat-sealing mechanisms, depending on the container type and product requirements, ensuring an airtight seal to maintain sterility during storage and transport.
Aseptic Liquid Filling Machines are critical for producing high-quality, sterile liquid products across multiple industries. Their ability to maintain a contamination-free environment, coupled with precise filling, sealing, and advanced automation, makes them indispensable for ensuring product safety, regulatory compliance, and operational efficiency.
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The incoming dry vial (sterilized & siliconised) are fed through the unscrambler and suitably guided on the moving delrin slat conveyor belt at the required speed of the correct placement below filling unit. The filling unit consists of Filling Head, Syringes & Nozzles which are used for liquid filling. The syringes are made of Stainless Steel 316L construction and both, glass as well as Stainless Steel syringes can be used. A Star Wheel is provided which holds the vial during filling operation. A sensor is provided for ”No Vial-No Filling” operation. Syringes are mounted on eccentric block and driving through bottom main gear box. Volume can be either increased or decreased by increasing or decreasing stroke length of piston as per filling size. Syringes is having non return valve for sucking and delivering situation to avoid volume variation. Liquid will reach to filling nozzles through silicon transparent pipe. Nozzle will be having Up and Down movement with help of cam mechanism and it will come down when vial will be hold by starwheel for filling operation and starts filling when it starts to move up and after completion of filling operation, starwheel delivers six vials together on conveyor for rubber stoppering operation. Stoppering unit consist of Starwheel, Vibrator unit and Bowl. The sterilized and siliconised rubber stoppers stored in the vibrator bowl moves vertically to the rubber stopper chute. The vial is hold firmly by starwheel, which will be in continuous rotary motion and vial which is coming from filling unit get in to starwheel and move in rotary direction along with starwheel, during movement it will pick up the rubber stopper from the exit end of the chute and rubber stopper will be pressed by fix single pressing roller, which is spring loaded. Then vial further move on conveyor and collected on out feed starwheel for next sealing operation.
Model | ALVF-40 | ALVF-80 | ALVF-120 | ALVF – 250 |
Filling Heads | Two | Four | Eight | Twelve |
Production Rate | Up to 40 Vials/Minute | Up to 80 Vials/Minute | Up to 150 Vials/Minute | Up to 250 Vials/Minute |
Vial Diameter | 15mm to 70mm | 15mm to 70mm | 15mm to 70mm | 15mm to 70mm |
Vial Height | 25mm to 140mm | 25mm to 140mm | 25mm to 140mm | 25mm to 140mm |
Filling Precision | ±1% | ±1% | ±1% | ±1% |
Power Required | 1 H.P. | 1.5 H.P. | 2 H.P. | 2 H.P. |
Electrical Characteristics | 440 Volts, 3 Phase, 50 Hertz | 440 Volts, 3 Phase, 50 Hertz | 440 Volts, 3 Phase, 50 Hertz | 440 Volts, 3 Phase, 50 Hertz |
Overall Dimension | 2050mm (L) x 850mm (W) x 1700mm (H) | 2200mm (L) x 850mm (W) x 1700mm (H) | 3000mm (L) x 945mm (W) x 1700mm (H) | 3500mm (L) x 945mm (W) x 1700mm (H) |
* 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.
These machines are designed to comply with strict regulatory standards, ensuring product safety and extended shelf life without refrigeration for shelf-stable products. They are suitable for both small-scale laboratory applications and high-volume commercial production.
The machine supports filling volumes from 2ml to 250ml. It achieves high filling accuracy of ±0.5% to ±1% using piston or peristaltic pumps. Available models include:
It handles vials with diameters of 15–70mm and heights of 25–140mm.
Key features include:
Sterilized vials are fed via an unscrambler onto a conveyor. They are positioned under filling nozzles (using SS 316L syringes) for precise dosing. A star wheel holds the vial during filling, with a “No Vial-No Filling” sensor. After filling, vials move to a stoppering unit where sterilized rubber stoppers are automatically placed and pressed. The entire process occurs in a sterile zone with unidirectional airflow, often integrated with isolators or RABS.
It is widely used in the Pharmaceutical, Biotech, Cosmetic, Food & Beverage, and Chemical industries. Main benefits include:
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Connect with our engineering team to discuss your specific production requirements. We provide customized, cGMP-compliant machinery solutions designed to optimize your manufacturing facility and maximize output.
Adinath International manufactures high-precision vial powder filling machines and complete packaging lines, providing reliable, hygienic, and efficient solutions for global pharmaceutical industries.
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