Four Head Vial Filler

Description

Four Head Vial Filler (also known as a Four Head Liquid Vial Filling and Rubber Stoppering Machine) is an automated pharmaceutical packaging machine designed for the precise filling and sealing of injectable liquids into glass vials. It is commonly used in sterile environments for producing injectables, such as vaccines, antibiotics, or other parenteral solutions, ensuring compliance with GMP (Good Manufacturing Practices) standards. The “four head” refers to the four simultaneous filling nozzles, which enable higher throughput compared to two-head models while maintaining accuracy.

In-Feed: Sterilized vials are loaded onto an unscrambler and fed via conveyor to the filling station.

Filling: Four vials are positioned under the nozzles by a star wheel. Nozzles descend, fill precisely (e.g., via piston pumps), and ascend, delivering ~0.5–1% accuracy.

Stoppering: Filled vials move to the stoppering wheel, where rubber bungs are picked and pressed in.

Out-Feed: Sealed vials exit via conveyor for capping, labeling, or inspection. The process is continuous and synchronized to avoid bottlenecks.

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

Salient Features of Four Head Vial Filler

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 Four Head 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 Four Head Vial Filler

Model	ALVF-80
Filling Heads	Four
Production Rate	Up to 80 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	1.5 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2200mm (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 Four Head Vial Filler

Better Efficiency & Throughput

Cost-Effective in the Long Run

Improved Filling Accuracy

Reduced Human Intervention

Consistency Across Batches

Key Components of Four Head Vial Filler

Compact and Integrated Design: Typically includes an in-feed turntable, stainless steel (SS) slat conveyor belt, filling station with four volumetric syringes/nozzles, and an integrated rubber stoppering unit. The machine frame is constructed from stainless steel for durability and easy cleaning.

Filling Mechanism: Uses a cam-driven system where nozzles move up and down for bottom-up filling, minimizing foaming, splashing, and air entrapment. It supports volumetric filling for liquids of varying viscosities, with optional simultaneous gassing (e.g., nitrogen purging) to maintain sterility.

Stoppering System: After filling, vials are transferred via star wheel to a rotary stoppering station, where rubber stoppers are fed from a vibratory chute and pressed into place using spring-loaded rollers.

Safety and Controls: Equipped with sensors to detect missing vials (preventing overfill or waste), variable speed drives, and PLC-based controls for easy operation. It often includes explosion-proof features for handling volatile liquids.

Vial Compatibility: Suitable for round glass vials ranging from 2ml to 50ml (change parts required for different sizes). Neck sizes and fill volumes are adjustable.

FAQ for Four Head Vial Filler

What is the production capacity of the Four Head Vial Filler?

The Four Head Vial Filler is designed for high-efficiency liquid filling, capable of processing up to 80 vials per minute. This speed is achieved through four simultaneous filling nozzles and a synchronized star-wheel transport system.

What range of vial sizes can this machine accommodate?

This machine is highly versatile and can handle a wide range of glass and plastic vials. It supports vial diameters from 15mm to 70mm and vial heights from 25mm to 140mm. Note that specific “change parts” may be required when switching between different vial dimensions.

How accurate is the filling process?

The machine utilizes a high-precision volumetric filling principle (typically via piston pumps or optional peristaltic pumps). It offers a filling precision of , ensuring consistent dosage and minimizing product wastage, which is critical for pharmaceutical applications.

Does the machine include a stoppering unit?

Yes, the Four Head Vial Filler is a compact, integrated unit. After the filling process, vials are automatically transferred to a rubber stoppering station. Here, sterilized rubber stoppers are fed from a vibratory bowl and pressed into the vials using a spring-loaded roller system before they exit the machine.

What materials are used in the construction of the machine?

To comply with strict GMP (Good Manufacturing Practice) standards, all contact parts are made from Stainless Steel 316L to prevent corrosion and contamination. The main machine framework and non-contact parts are constructed from Stainless Steel 304 for durability and easy sterilization.

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