Automatic Vial Filler

Description

Automatic Vial Filler is a specialized machine used primarily in the pharmaceutical, biotechnology, and cosmetics industries to fill vials (small glass or plastic containers) with liquid or semi-liquid products in a precise, sterile, and high-speed manner. Vial Filler machines are critical for ensuring accuracy, consistency, and compliance with regulatory standards like cGMP (current Good Manufacturing Practices). 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.

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

Salient Features of Automatic Vial Filler

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 Automatic Vial Filler

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 Automatic Vial Filler

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 Automatic Vial Filler

High accuracy (±0.5% fill volume)

Reduced contamination risk

Scalable for small batch to high-volume production

Full traceability and data logging

Key Components of Automatic Vial Filler

Filling Mechanisms:
- Peristaltic pumps – Ideal for sterile, low-viscosity liquids; easy to clean.
- Piston pumps – Suitable for viscous liquids or suspensions.
- Time-pressure filling – Used for high-precision, foam-sensitive products.
- Mass flow filling – For high-accuracy filling based on weight.

Vial Handling:
- Automatic infeed systems (e.g., rotary tables, conveyor belts).
- Denesting and positioning of vials.
- Supports various vial sizes (2mL to 100mL typically).

Sterility & Cleanliness:
- Laminar airflow hoods (LAF) or isolators.
- Clean-in-place (CIP) and sterilize-in-place (SIP) capabilities.
- HEPA filtration.

Capping & Sealing:
- Integrated crimping or screw-capping stations.
- Stopper placement (rubber stoppers for injectables).

Controls & Monitoring:
- PLC (Programmable Logic Controller) with HMI touchscreen.
- Fill volume verification via check-weigh systems or vision inspection.
- Rejection of under/over-filled or defective vials.

FAQ for Automatic Vial Filler

What is an Automatic Vial Filler and what is it used for?

An Automatic Vial Filler is a high-precision, fully automatic machine designed to fill sterile liquid or semi-liquid products into glass or plastic vials. It is widely used in the pharmaceutical, biotechnology, and cosmetic industries for packaging injectable drugs, vaccines, antibiotics, and other parenteral formulations. The machine automatically handles vial feeding, filling, and transfers the vials for rubber stoppering, ensuring cGMP compliance, high accuracy, and minimal risk of contamination through reduced human intervention.

What are the available models and production speeds of the Automatic Vial Filler?

We offer four models to suit different production requirements:

– ALVF-40: 2 filling heads – up to 40 vials per minute
– ALVF-80: 4 filling heads – up to 80 vials per minute
– ALVF-120: 8 filling heads – up to 150 vials per minute
– ALVF-250: 12 filling heads – up to 250 vials per minute

Speed is adjustable via a variable AC frequency drive. The machine includes a digital vial counter for accurate batch tracking and is ideal for both small-batch and large-scale commercial production.

What vial sizes and fill volumes can the Automatic Vial Filler handle?

The Automatic Vial Filler can process vials with:
– Diameter: 15 mm to 70 mm
– Height: 25 mm to 140 mm
– Fill Volume Range: 2 ml to 250 ml

It supports a wide range of liquid and suspension products. All product contact parts are made of AISI SS 316L for superior corrosion resistance and easy cleaning. Quick changeover with minimal change parts makes it flexible for different vial formats.

What is the filling accuracy and how does the machine ensure product safety?

The machine delivers excellent filling accuracy of ±1% (can reach ±0.5% depending on product and pump type). Safety and sterility are ensured through:
– “No Vial – No Filling” system
– “No Vial – Machine Stop” interlock
– Minimal human contact
– No cross-contamination design

It is suitable for operation in Class 100 / ISO 5 cleanrooms and complies with cGMP, FDA, and EU guidelines. Options like peristaltic pumps are available for shear-sensitive or highly sterile products.

What are the key benefits and optional features of the Automatic Vial Filler?

Key benefits include:
– High-speed, precise, and consistent filling with very low product wastage
– Reduced labor costs and contamination risks
– Easy integration into complete injectable lines (vial washing → filling → stoppering → capping)
– Flexibility for small to large batch production
– Simple operation with variable speed control and digital counter

Optional features include PLC with HMI touchscreen, IQ/OQ documentation, laminar airflow hood, CIP/SIP system, and different pump technologies (piston or peristaltic) based on your product viscosity and sterility requirements.

Countries We Export to

Partner with Industry Experts

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.

GET A QUOTE!