Six Head Vial Filling Machine

Q: How does the machine ensure hygiene and sterile operation?

The machine is built strictly according to cGMP standards . All liquid contact parts are made from Stainless Steel 316L , while the rest of the structure is SS 304. It also features a 'bottom-up' filling mechanism where nozzles descend into the vials to prevent foaming and splashing, which is essential for maintaining a sterile process.

Description

Six Head Vial Filling Machine is an automated pharmaceutical packaging equipment primarily used for filling sterile vials with injectable liquids (such as pharmaceuticals, vaccines, or biotech solutions) and subsequently applying rubber stoppers for sealing. It features six independent filling heads, enabling high-speed, precise operations in a controlled sterile environment, often under laminar airflow protection to comply with GMP (Good Manufacturing Practice) standards. This machine is ideal for medium to large-scale production, handling vials ranging from 2ml to 50ml in size, and can incorporate additional features like nitrogen purging to minimize oxygen exposure.

Vial Feeding: Empty, dry vials are fed via an unscrambler onto a Delrin slat conveyor belt, guided precisely to the filling station.

Filling: Vials are held by a star wheel under the six filling heads. Nozzles descend for liquid injection while moving with the vial; sensors ensure accurate volume.

Stoppering: Filled vials advance to the stoppering unit, where rubber bungs are oriented, vibrated into position, and pressed via vacuum hold discs.

Output: Completed vials exit onto a conveyor for capping, labeling, or further processing, with outputs accumulating in batches.

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Salient Features of Six Head Vial Filling Machine

Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
In-feed Turn Table/ Unscrambler for automatic feeding of objects, “No Vial – Machine Stop” System.
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 cross contamination.
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)

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

Working Principle of Six 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.

Key Components of Six Head Vial Filling Machine

Sterile Design: Constructed with stainless steel (SS 316 for liquid-contact parts and SS 304 for others) to ensure easy cleaning and corrosion resistance. Designed for operation in Class 100 cleanrooms with redesigned unscramblers to eliminate dead spots.

Filling Mechanism: Utilizes volumetric piston pumps, peristaltic pumps, or time-pressure systems with stainless steel syringes and nozzles. Each of the six heads operates independently for continuous production without downtime.

Motion-Type Filling: Nozzles move synchronously with vials during filling to prevent spillage and ensure accuracy (±1% volume tolerance), supporting speeds up to 150 vials per minute.

Stoppering System: Integrated vacuumetric or vibratory rubber bung applicator for precise placement of stoppers post-filling.

Safety and Controls: Includes sensors for vial detection, no-vial/no-fill interlocks, and intuitive PLC-based controls with CE certification.

Optional Enhancements: Nitrogen flushing before/after filling, inline inspection for particles or defects, and tool-less format changes for different vial sizes.

FAQ for Six Head Vial Filling Machine

What is the output capacity of the Six Head Vial Filling Machine?

The Six Head model is designed for high-speed production requirements. It can achieve a production rate of 120 to 150 vials per minute, depending on the fill volume, vial neck diameter, and the flow characteristics of the liquid. This makes it ideal for large-scale pharmaceutical manufacturing.

What fill volumes can the machine handle?

This machine is highly flexible and can be configured to fill volumes ranging from 2ml to 250ml. The use of six high-precision volumetric syringes ensures an accuracy of ±1%, providing consistent dosing across all containers in a high-speed environment.

Does the machine include an integrated stoppering unit?

Yes. To ensure maximum sterility and efficiency, the Six Head Vial Filler features an integrated automatic rubber stoppering station. Immediately after filling, vials are moved via a star wheel to the stoppering unit where sterilized bungs are picked and placed, minimizing the time the product is exposed to the environment.

How does the machine ensure hygiene and sterile operation?

The machine is built strictly according to cGMP standards. All liquid contact parts are made from Stainless Steel 316L, while the rest of the structure is SS 304. It also features a “bottom-up” filling mechanism where nozzles descend into the vials to prevent foaming and splashing, which is essential for maintaining a sterile process.

What safety mechanisms are in place for missing vials?

To prevent expensive liquid wastage and equipment mess, the machine is equipped with a “No Vial – No Filling” sensor system. If a vial is missing from the conveyor or star wheel, the filling nozzles for that specific position will not discharge. Similarly, a “No Vial – No Stopper” sensor ensures that rubber bungs are not released if a vial is not present at the stoppering station.

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