Injection Vial Filling Machine

Description

Injection Vial Filling Machine is a specialized piece of pharmaceutical equipment designed to automate the precise filling of sterile glass vials with injectable liquids (such as vaccines, antibiotics, or biopharmaceuticals) or dry powders, followed by sealing with rubber stoppers and caps. Vial Filling Machine ensure high levels of sterility, accuracy, and efficiency, complying with stringent regulatory standards like cGMP, FDA, WHO GMP, and EU guidelines. They are essential in aseptic processing to minimize contamination risks and support high-volume production, often operating under laminar airflow or isolator systems.

Vial Preparation: Sterilized vials (pre-washed with Water for Injection and depyrogenated via tunnels) are fed via an in-feed turntable and conveyor.

Filling: Vials are positioned under filling nozzles; liquid or powder is dispensed accurately based on volume sensors. Nitrogen gassing may occur before/after to prevent oxidation.

Stoppering: Rubber stoppers are partially inserted using vacuum or mechanical systems to seal the vial while allowing for final capping.

Capping and Sealing: Aluminum caps are applied and crimped for tamper-evident security.

Output: Filled vials exit via out-feed conveyor for downstream processes like inspection, labeling, or packaging. The entire process is monitored for sterility and rejects defective units.

Speed: Up to 120–400 vials per minute, depending on model, vial size, and product type.

Applications: Ideal for pharmaceuticals like COVID-19 vaccines, oncology drugs, and injectables. Used in standalone mode or full lines including washing, freeze-drying, and track-and-trace systems.

Benefits: Reduces human intervention, minimizes waste/spillage, and ensures batch consistency. Customizable for small/large-scale production, with options for isolator integration to handle high-potency drugs.

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 Injection Vial Filling Machine

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 Injection Vial Filling Machine

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 Injection Vial Filling Machine

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.

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 Injection Vial Filling Machine

High Precision and Accuracy

Increased Production Speed and Efficiency

Reduced Human Error and Contamination Risk

Improved Consistency and Quality Control

Enhanced Sterility and Product Integrity

Lower Downtime and Maintenance

Key Components of Injection Vial Filling Machine

Construction: Typically made from stainless steel to prevent corrosion and ensure easy cleaning/validation. Includes in-feed turntables, slat conveyors, and out-feed systems for smooth vial handling.

Filling Mechanism: Uses peristaltic, volumetric, or servo-driven pumps for ±1% filling accuracy. Supports pre- and post-gassing to displace oxygen and maintain sterility.

Stoppering and Capping: Integrates rubber bunging (stoppering) and aluminum cap sealing in a monobloc design, reducing contamination exposure.

Safety Features: “No vial, no fill” sensors, digital counters, and variable AC frequency drives for speed control. Often equipped with inbuilt laminar airflow for Class 100 sterile environments.

Versatility: Handles vial sizes from 2ml to 250ml, various liquid viscosities, and powder formulations. Options for multiple filling heads and integration with washing, drying, inspection, and labeling stations.

FAQ for Injection Vial Filling Machine

What is an Injection Vial Filling Machine?

An Injection Vial Filling Machine is a specialized pharmaceutical equipment designed for accurately filling sterile liquids (or powders) into glass vials used for injectable drugs, vaccines, and biologics. It typically integrates filling, stoppering, and often sealing (crimping) in an aseptic environment to maintain product sterility and ensure precise dosing. These machines are essential in GMP-compliant production lines for high-accuracy, high-speed, and contamination-free filling.

What are the key advantages of using an Injection Vial Filling Machine?

The main advantages include:

High dosing accuracy and consistency (minimizing product waste)
Increased production speed (hundreds to thousands of vials per hour)
Reduced human intervention, lowering contamination risk in sterile environments
Better compliance with regulatory standards (FDA, GMP, WHO)
Cost savings through lower labor and reduced rejects
Flexibility to handle different vial sizes and formulations

Automation helps pharmaceutical manufacturers scale production while maintaining quality and safety.

What is the typical production capacity of an Injection Vial Filling Machine?

Production capacity varies by model and configuration. Most machines range from 30–60 vials per minute (small to medium scale) up to 200–300+ vials per minute in high-speed rotary or multi-head models. Factors affecting output include the number of filling heads, vial size (2ml to 100ml+), and whether it’s a mono-block or integrated line. Contact us for models matching your required output.

How does an Injection Vial Filling Machine ensure sterility and accuracy?

These machines are built for aseptic processing and usually operate under ISO Class 5 / Grade A conditions, often with RABS or isolator integration. Accuracy is achieved through advanced systems like peristaltic pumps, servo-driven pistons, or mass flow meters. Features such as no-contact filling paths, in-process weight checking, automatic reject systems, and easy-to-clean SS316 contact parts help maintain sterility and dosage precision within ±0.5–1% variation.

What factors should I consider before buying an Injection Vial Filling Machine?

Key factors include:

Required production capacity and batch size
Vial size range and changeover flexibility
Type of product (liquid, viscous, or powder)
Level of automation (semi-automatic vs. fully automatic)
Cleanroom compatibility (RABS/Isolator)
Compliance with cGMP, FDA, and other standards
After-sales service, spare parts availability, and maintenance ease

Our experts can help you select the right model based on your specific requirements.

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