Aseptic Vial Filler Capper

Q: What are the available models and production capacities of the Aseptic Vial Filler Capper?

We offer multiple models based on production needs: - ALVF-40 – Up to 40 vials per minute - ALVF-80 – Up to 80 vials per minute - ALVF-120 – Up to 150 vials per minute - ALVF-250 – Up to 250 vials per minute The machine handles vial sizes from 2 ml to 250 ml with diameters of 15 mm to 70 mm. Output depends on vial size, fill volume, and product characteristics. Custom monoblock configurations with higher speeds are also available.

Q: How does the Aseptic Vial Filler Capper maintain sterility during operation?

The machine operates under Laminar Air Flow (Class 100) with options for RABS or isolator technology. It features advanced “No Vial – No Filling”, “No Stopper – No Capping” sensors, and can be equipped with Vaporized Hydrogen Peroxide (VHP) decontamination. All product contact parts are made of SS 316L, and the system supports CIP/SIP (Clean-in-Place / Sterilize-in-Place). Optional nitrogen flushing further protects oxygen-sensitive products.

Description

Aseptic Vial Filler Capper is a fully automated, high-precision machine designed for Sterile Filling and Capping of liquid or lyophilized pharmaceutical products into glass or plastic vials under ISO 5 (Class 100) cleanroom conditions. It ensures zero microbial contamination through advanced isolation technology, in-line sterilization, and closed-system processing—critical for injectables, biologics, and high-potency drugs. This compact, cGMP-compliant system integrates three critical operations — filling, stoppering, and capping — in a single unit, minimizing footprint, reducing contamination risks, and improving production efficiency. It is ideal for aseptic processing of vaccines, antibiotics, biologics, serums, and other parenteral products under controlled Class 100 / ISO 5 environments.

This machine ensures compliance with cGMP standards for sterile injectable filling. If you need details on specific models, pricing, or comparisons with multi-head machines, let me know!

Salient Features of Aseptic Vial Filler Capper

Suitable for the filling Volume of 2ml to 250ml.
Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
No cross contamination.
Easy to validate filling system for small/large batch production.
All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.
Variable A.C. frequency drive for speed adjustment.

Digital Vial Counter for counting production output.
In-feed Turn Table/ Unscrambler for automatic feeding of objects.
On-line Mechanism.
“No Vial – No Filling” System.
“No Vial – Machine Stop” System.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Aseptic Vial Filler Capper

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 Aseptic Vial Filler 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.

Types of Vial Filling Machine

Automatic Vial Filling Machine

High Speed Vial Filling Machine

Vial Liquid Filling Machine

Vial Powder Filling Machine

Automatic Vial Filling and Rubber Stoppering Machine

Lab Scale Vial Filling Stoppering & Cap Sealing Machine

Injectable Vial Powder Filling & Stoppering Machine

Peristaltic Pump based Vial Filling Machine

Applications of Vial Filling Machine

Advantages of Aseptic Vial Filler Capper

Superior Sterility Assurance and Reduced Contamination Risk

High Filling Accuracy and Product Quality

Compact Monoblock Design – Space and Cost Efficiency

Increased Production Efficiency and Speed

Regulatory Compliance and Easier Validation

Minimal Product Wastage and Operational Cost Savings

Key Components of Aseptic Vial Filler Capper

Vial Infeed System: Washed & depyrogenated vials enter via conveyor or turntable

Filling Station: Peristaltic pumps, piston pumps, or time-pressure systems for precise filling

Stoppering Unit: Inserts rubber stoppers (full or partial) under vacuum or mechanically

Capping Station: Applies aluminum/plastic flip-off or tear-off caps; crimps securely

Isolator / RABS: Restricted Access Barrier System or full isolator for aseptic zone

In-Process Controls: Fill weight check, stopper presence, cap integrity

Gas Purging (Optional): Nitrogen or argon flushing to reduce oxygen

FAQ for Aseptic Vial Filler Capper

What is an Aseptic Vial Filler Capper and why is it used?

An Aseptic Vial Filler Capper is a fully automatic monoblock machine that performs filling, rubber stoppering, and aluminum sealing of vials in a single continuous operation under a strictly sterile environment. It is mainly used in the pharmaceutical and biotech industries for the aseptic production of injectable liquids, vaccines, biologics, and other sterile parenteral products. The machine minimizes human intervention, ensures highest sterility assurance, and complies with cGMP and USFDA regulatory requirements.

What are the available models and production capacities of the Aseptic Vial Filler Capper?

We offer multiple models based on production needs:
– ALVF-40 – Up to 40 vials per minute
– ALVF-80 – Up to 80 vials per minute
– ALVF-120 – Up to 150 vials per minute
– ALVF-250 – Up to 250 vials per minute

The machine handles vial sizes from 2 ml to 250 ml with diameters of 15 mm to 70 mm. Output depends on vial size, fill volume, and product characteristics. Custom monoblock configurations with higher speeds are also available.

How does the Aseptic Vial Filler Capper maintain sterility during operation?

The machine operates under Laminar Air Flow (Class 100) with options for RABS or isolator technology. It features advanced “No Vial – No Filling”, “No Stopper – No Capping” sensors, and can be equipped with Vaporized Hydrogen Peroxide (VHP) decontamination. All product contact parts are made of SS 316L, and the system supports CIP/SIP (Clean-in-Place / Sterilize-in-Place). Optional nitrogen flushing further protects oxygen-sensitive products.

What is the working principle of the Aseptic Vial Filler Capper?

Sterilized vials enter the machine via an infeed turntable and are precisely positioned under the filling stations by a star wheel. Volumetric piston pumps with SS 316L syringes accurately fill the product (±1% accuracy). The vials then move to the stoppering station where pre-sterilized rubber stoppers are placed and pressed, followed by the capping station for aluminum seal application. The entire process is continuous, gentle, and designed to maintain aseptic conditions with minimal particle generation.

What are the main advantages of using an Aseptic Vial Filler Capper?

Key advantages include:
– Compact monoblock design that saves cleanroom space and reduces validation efforts
– High filling accuracy with very low product wastage
– Reduced risk of contamination due to minimal human intervention
– Faster changeover and easier maintenance
– Compliance with international regulatory standards
– Improved production efficiency and lower operational costs

It is ideal for both small-batch and high-volume sterile injectable manufacturing.

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