Two Syringe Vial Filling Machine

Q: What is the production capacity and vial size range of the Two Syringe Vial Filling Machine?

The machine (Model ALVF-40) can fill up to 40 vials per minute. It handles vial diameters from 15mm to 70mm, heights from 25mm to 140mm, and filling volumes from 2ml to 250ml. This makes it suitable for a wide range of injectable products, including vaccines, antibiotics, and biologics, in both small pilot batches and medium commercial runs.

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

The machine offers a filling accuracy of ±1%, which can reach up to ±0.5% depending on the liquid viscosity and volume. It uses precision piston or peristaltic pumps with non-return valves to ensure consistent dosing and prevent backflow. Advanced features like the “No Vial – No Filling” system further reduce product wastage and ensure high repeatability.

Q: What materials are used in the product contact parts?

All product contact parts are made from high-quality Stainless Steel 316L (syringes, nozzles, and filling paths), while the framework is *Stainless Steel 304. The machine uses non-toxic silicon transparent tubing and a Delrin slat conveyor. These materials ensure cGMP compliance , easy cleaning, and suitability for sterile environments like Class 100 cleanrooms.

Description

Two Syringe Vial Filling Machine is a specialized semi-automatic or automatic pharmaceutical filling system designed for precise liquid filling of glass vials, commonly used in injectable drug production. It features two precision-engineered filling syringes equipped with non-return valves to ensure consistent volume delivery and prevent backflow during operation. This dual-syringe configuration enables efficient handling of small to medium batch sizes, with fill accuracies of ±0.5% or better, making it ideal for sterile environments like Class 100 cleanrooms. The machine supports vial sizes up to 100 ml and integrates filling with optional stoppering, gassing, and capping processes.

Vial Feeding: Sterilized vials enter via an unscrambler and are guided onto a Delrin slat conveyor at controlled speed.

Positioning: Vials are indexed under the filling head by a starwheel.

Filling: Syringes suck liquid from a reservoir, and nozzles lower to fill vials. Non-return valves maintain accuracy.

Post-Filling: Vials advance for optional nitrogen gassing, rubber stopper insertion, and capping.

Primary Use: Aseptic filling for pharmaceuticals, biotech, and clinical trials, ensuring minimal shear on sensitive products like vaccines or biologics.

Advantages: Compact benchtop or inline design for labs/R&D; sterile, tool-less changeovers; reduces contamination risk with single-use fluid paths. Scalable from pilot (e.g., 50-100 vials/batch) to small commercial runs.

Compliance: Meets cGMP standards, with options for VPHP decontamination and isolator integration.

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

Salient Features of Two Syringe 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 Syringe 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 Syringe 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 Syringe Vial Filling Machine

Higher Production Output

Improved Efficiency and Reduced Cycle Time

Compact Design with Better Throughput

Consistent Filling Accuracy with Minimal Wastage

Cost-Effective Upgrade

Lower Maintenance and Easy Operation

Key Components of Two Syringe Vial Filling Machine

Filling Mechanism: Liquid product is drawn into the two syringes via a peristaltic or volumetric pump, then dispensed through silicon transparent tubing to nozzles. The nozzles employ a cam-driven up-and-down movement: they descend to align with vials held by a starwheel, fill during ascent, and deliver two vials simultaneously to the conveyor for downstream operations like rubber stoppering.

Construction: Built with GMP-compliant materials, including AISI SS 316L for syringes and nozzles, non-toxic synthetic rubber tubing, and a stainless steel slat conveyor belt. It includes an unscrambler for incoming sterilized, siliconized vials.

Controls and Automation: Equipped with an eccentric pre-gassing unit, electronic weigh-scale integration for real-time fill adjustments, and a compact control panel for easy parameter setting (e.g., fill volume, speed).

Versatility: Processes aqueous solutions, suspensions, oils, and creams; adaptable for nested ready-to-use vials. Some models allow quick format changes for syringes or cartridges on the same line.

FAQ for Two Syringe Vial Filling Machine

What is a Two Syringe Vial Filling Machine?

A Two Syringe Vial Filling Machine is a compact, high-precision liquid filling system designed for aseptic filling of injectable liquids into glass vials. It features two filling heads (syringes) with non-return valves, enabling higher output than single-head machines while maintaining excellent accuracy. It is ideal for small to medium batch production in pharmaceutical, biotech, and cosmetic industries. The machine supports bottom-up filling to minimize foaming and supports optional stoppering and nitrogen gassing.

What is the production capacity and vial size range of the Two Syringe Vial Filling Machine?

The machine (Model ALVF-40) can fill up to 40 vials per minute. It handles vial diameters from 15mm to 70mm, heights from 25mm to 140mm, and filling volumes from 2ml to 250ml. This makes it suitable for a wide range of injectable products, including vaccines, antibiotics, and biologics, in both small pilot batches and medium commercial runs.

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

The machine offers a filling accuracy of ±1%, which can reach up to ±0.5% depending on the liquid viscosity and volume. It uses precision piston or peristaltic pumps with non-return valves to ensure consistent dosing and prevent backflow. Advanced features like the “No Vial – No Filling” system further reduce product wastage and ensure high repeatability.

What materials are used in the product contact parts?

All product contact parts are made from high-quality Stainless Steel 316L (syringes, nozzles, and filling paths), while the framework is *Stainless Steel 304. The machine uses non-toxic silicon transparent tubing and a Delrin slat conveyor. These materials ensure cGMP compliance, easy cleaning, and suitability for sterile environments like Class 100 cleanrooms.

What optional features are available with the Two Syringe Vial Filling Machine?

You can enhance the machine with several options, including:
– PLC system with HMI (Graphical User Interface)
– Nitrogen flushing / pre-gassing
– Rubber stoppering unit
– Digital vial counter
– Variable AC frequency drive for speed control

These options make the machine more versatile for fully automated lines and improve process validation (IQ/OQ documentation available).

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Two Syringe Vial Filling Machine

Description

Salient Features of Two Syringe Vial Filling Machine

Working Principle of Two Syringe Vial Filling Machine

Technical Specification of Two Syringe Vial Filling Machine

Types of Vial Filling Machine

Applications of Vial Filling Machine

Advantages of Two Syringe Vial Filling Machine

Higher Production Output

Improved Efficiency and Reduced Cycle Time

Compact Design with Better Throughput

Consistent Filling Accuracy with Minimal Wastage

Cost-Effective Upgrade

Lower Maintenance and Easy Operation

Key Components of Two Syringe Vial Filling Machine

FAQ for Two Syringe Vial Filling Machine

Countries We Export to

Partner with Industry Experts

Countries We Export to

Partner with Industry Experts

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