A Plastic Vial Filler Capper is an automated or semi-automated packaging machine designed for efficiently filling and sealing plastic vials (small containers typically used for liquids, semi-solids, or powders in industries like pharmaceuticals, cosmetics, nutraceuticals, and essential oils). These machines are often compact, monoblock (single-unit) designs that integrate filling, stoppering (if needed), and capping operations to ensure sterility, precision, and high throughput in cleanroom or aseptic environments. They comply with standards like cGMP for safety and hygiene.
Vial Filler and Capper Machine Video
Key Features and Components
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Filling Mechanism: Utilizes piston pumps, volumetric syringes, or peristaltic pumps to dispense accurate volumes with precision up to ±1%. Includes sensors for “no vial, no fill” to prevent waste.
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Capping System: Automatically places and screws or crimps caps using servo torque control for adjustable tightness, ensuring tamper-evident seals.
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Conveyor and Handling: Stainless steel slat belts or turntables feed vials into position; star wheels hold vials steady during processing. Supports ready-to-use (RTU) plastic vials in tubs or nests.
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Sterility and Cleaning: Designed for laminar flow protection, with easy-to-clean surfaces, minimal dead zones, and options for pre/post-gassing to maintain product integrity.
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Speed and Capacity: Up to 120–600 vials per minute, depending on model; suitable for batch sizes in sterile areas.
Common Applications
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Pharmaceuticals: Filling injectable liquids, vaccines, or oncology drugs into plastic vials for safe storage and transport.
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Cosmetics/Nutraceuticals: Packaging serums, oils, or supplements with high chemical resistance to prevent interactions.
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Other: Essential oils, beverages, or solvents requiring precise dosing and secure closure.
Exclusive Features of Vial Filling and Sealing Machine
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Compact footprint cGMP complied models.
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2ml to 250ml fill dosage compatibility.
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Filling accuracy of ±0.5% – 1% depends upon fluid & vial types.
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“No Vial – No Filling” system feature.
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In-feed Turn Table/ Unscrambler attached with the machine for automatic feeding of vials.
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All Contact Parts Made from AISI SS 316L & framework by AISI SS 304.
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No cross contamination.
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Easy to validate filling system for small/large batch production.
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Variable A.C. frequency drive for speed adjustment.
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Digital Vial Counter for counting production output.
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On-line Mechanism.
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IQ/OQ validation documents can be offered.
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PLC system with Graphical User Interface. (Optional)
Process Operation of Vial Filling and Capping
The incoming dry vials (sterilized and siliconized) 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; Syringes & Nozzles are made of AISI SS 316L materials. 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 increase & decrease 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 reaches to filling nozzles through silicon transparent pipe. Nozzles having up & down movement with help of cam mechanism, and it come down when vial hold by starwheel for filling operation and starts filling when it starts to move up and after completion of filling operation, starwheel delivers two vials together on conveyor for rubber stoppering operation.
Stoppering unit consist of Star wheel, Vibrator unit and Bowl. The sterilized and siliconized 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 picks up the rubber stopper from the exit end of the chute and rubber stopper 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.
Technical Specification of Vial Filler and Capper
| 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 |
| Input Specification | ||||
| 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.
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