Two Head Vial Filling Machine

Q: What is a Two Head Vial Filling Machine?

The Two Head Vial Filling Machine (Model: ALVF-40), also known as Two Head Automatic Vial Filling and Rubber Stoppering Machine, is a compact monoblock system designed for precise aseptic filling of sterile injectable liquids into glass vials followed by rubber stoppering. It features two filling heads that operate simultaneously using piston or peristaltic pumps with bottom-up filling technology. This makes it ideal for small to medium batch production in sterile environments under laminar airflow while meeting cGMP standards.

Q: What is the filling accuracy of the Two Head Vial Filling Machine?

The machine delivers a filling accuracy of ±1% , which can reach up to ±0.5% depending on the liquid characteristics and volume. It includes advanced safety features such as “No Vial – No Filling” and “No Vial – Machine Stop” systems to prevent wastage and ensure consistent, precise dosing for every vial.

Description

Two Head Vial Filling Machine, often referred to as a Two Head Automatic Vial Filling and Rubber Stoppering Machine, is a compact, semi-automatic or fully automatic pharmaceutical packaging equipment designed primarily for filling sterile injectable liquids into glass vials and then sealing them with rubber stoppers. This machine is ideal for small to medium batch productions in sterile environments, such as under laminar airflow protection, ensuring compliance with cGMP standards and minimizing contamination risks. It features two filling heads for efficient operation, handling round vials typically ranging from 2ml to 50ml in size.

Vial Feeding: Sterilized and siliconized vials are fed via an unscrambler or turntable onto a Delrin slat conveyor belt, positioned accurately under the filling heads using a star wheel.

Filling: The two heads simultaneously fill liquid into vials held by the star wheel. Syringes (glass or SS) draw and dispense the exact volume, with nozzles descending during filling and ascending afterward.

Stoppering: Filled vials move to the stoppering station, where rubber stoppers are oriented via a vibrating bowl and chute, then pressed vertically onto the vials.

Discharge: Sealed vials are ejected onto the conveyor for further capping (if needed) or packaging. The entire process operates in a sterile zone, often with laminar airflow.

This bottom-up filling technique handles both low- and high-viscosity liquids efficiently, with independent head operation allowing continuous production even if one head encounters an issue.

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

Salient Features of Two Head Vial Filling Machine

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

Digital Vial Counter for counting production output.
“No Vial – Machine Stop” System.
On-line Mechanism., “No Vial – No Filling” System.
Easy to validate filling system for small/large batch production.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Two Head 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 Two Head Vial Filling Machine

Model	ALVF-40
Filling Heads	Two
Production Rate	Up to 40 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	1 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2050mm (L) x 850mm (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 Two Head Vial Filling Machine

Higher Production Output

Improved Efficiency and Reduced Cycle Time

Compact Footprint with Better Throughput

Consistent Filling Accuracy and Minimal Wastage

Cost-Effective and Easy to Validate

Lower Maintenance and Labor Requirement

Key Components of Two Head Vial Filling Machine

Construction and Materials: Built with stainless steel for durability, corrosion resistance, and easy cleaning. The machine often includes a matt-finished exterior to reduce glare in cleanrooms.

Filling Mechanism: Utilizes volumetric piston pumps or syringes with adjustable stroke lengths for precise filling volumes. Nozzles move up and down via a cam mechanism to prevent splashing and foaming.

Stoppering System: Integrated rubber stoppering unit presses 13mm or 20mm rubber stoppers with a fixed roller or vacuum hold disc, ensuring secure sealing without vial breakage.

Safety and Efficiency Features:
- “No Vial, No Fill” sensor to prevent liquid wastage.
- Nitrogen flushing for oxygen-sensitive products.
- Minimal distance between filling and stoppering units to reduce exposure to contaminants.
- Easy changeover for different vial sizes without major adjustments.

Controls: Equipped with a compact electrical panel, AC drive for speed control, and optional touchscreen interface for user-friendly operation.

FAQ for Two Head Vial Filling Machine

What is a Two Head Vial Filling Machine?

The Two Head Vial Filling Machine (Model: ALVF-40), also known as Two Head Automatic Vial Filling and Rubber Stoppering Machine, is a compact monoblock system designed for precise aseptic filling of sterile injectable liquids into glass vials followed by rubber stoppering.

It features two filling heads that operate simultaneously using piston or peristaltic pumps with bottom-up filling technology. This makes it ideal for small to medium batch production in sterile environments under laminar airflow while meeting cGMP standards.

What is the production capacity of the Two Head Vial Filling Machine?

The Two Head Vial Filling Machine has a production output of up to 40 vials per minute.

It can handle vial diameters from 15mm to 70mm and heights from 25mm to 140mm, with filling volumes ranging from 2ml to 250ml. This capacity makes it perfect for scaling up from single-head machines without moving to large multi-head rotary systems.

What is the filling accuracy of the Two Head Vial Filling Machine?

The machine delivers a filling accuracy of ±1%, which can reach up to ±0.5% depending on the liquid characteristics and volume.

It includes advanced safety features such as “No Vial – No Filling” and “No Vial – Machine Stop” systems to prevent wastage and ensure consistent, precise dosing for every vial.

What are the key features of the Two Head Vial Filling Machine?

Key features include:

Dual filling heads for higher throughput
Bottom-up filling with diving nozzles to minimize foaming and splashing
Variable AC frequency drive for speed control
Digital vial counter
All product contact parts in Stainless Steel 316L and framework in SS 304
Easy format changeover and quick cleaning
Independent head operation for continuous production
Optional PLC system with HMI and Nitrogen flushing
IQ/OQ documentation support

The compact design (2050mm L × 850mm W × 1700mm H) ensures it fits easily in most cleanroom setups.

What are the advantages of the Two Head Vial Filling Machine?

The main advantages are:

Nearly double the output (40 vials/min) compared to single-head machines
Better efficiency and reduced cycle time for medium batch production
Compact footprint with higher productivity
Consistent accuracy with minimal product wastage
Cost-effective upgrade path from single-head to higher-volume needs
Easy validation, low maintenance, and suitability for both low and high-viscosity liquids

It is widely used in pharmaceutical, biotech, veterinary, cosmetic, and chemical industries for filling vaccines, antibiotics, biologics, suspensions, and other sterile liquids.

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