Eight Syringe Vial Filler

Q: How does the machine ensure high filling accuracy?

The machine utilizes eight high-precision AISI SS 316L syringes equipped with non-return valves. These valves prevent backflow and volume variation, allowing the machine to maintain a strict filling tolerance of ±0.5% to ±1% .

Q: Does the machine meet international pharmaceutical standards?

Yes, the Eight Syringe Vial Filler is built for cGMP-compliant environments. All contact parts are made from Stainless Steel 316L , and the main framework is constructed from Stainless Steel 304 . It is also designed for easy validation and can be provided with IQ/OQ documentation to support regulatory requirements in the biotech and pharmaceutical industries.

Description

Eight Syringe Vial Filler is a Automatic Pharmaceutical Filling Machine designed for precise, high-volume dispensing of liquid formulations into sterile vials. It utilizes eight stainless steel (SS 316L) syringes equipped with non-return valves to ensure consistent volume delivery and prevent backflow or variation during the filling process. This configuration allows for simultaneous filling of up to eight vials per cycle, achieving output speeds of 2,400–4,000 vials per hour, depending on vial size, liquid viscosity, and operational settings. These machines are commonly used in GMP-compliant environments for injectable drugs, vaccines, or biotech products, emphasizing sterility, accuracy (±0.5–1% fill tolerance), and minimal particle generation.

Vials enter via conveyor and are positioned under the 8-nozzle filling head.

Nozzles descend, fill under controlled pressure, then ascend.

Star wheel advances vials to stoppering station for plug insertion.

Vials exit to capping/labeling line.

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Salient Features of Eight Syringe 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 Eight Syringe 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 Eight Syringe Vial Filler

Model	ALVF-120
Filling Heads	Eight
Production Rate	Up to 150 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	2 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	3000mm (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 Eight Syringe Vial Filler

High Production Throughput

Exceptional Dosing Accuracy

cGMP Compliance and Sterility

Efficient Resource Management

Key Components of Eight Syringe Vial Filler

Filling Mechanism: Eccentric cam-driven syringes mounted on a rotary or linear station. Liquid is drawn from a reservoir through transparent silicone tubing and dispensed via diving nozzles that lower into the vial neck during filling and retract afterward to avoid drips. Pre- and post-nitrogen flushing options are available for oxygen-sensitive products.

Vial Handling: Incoming sterilized, siliconized vials are fed via a slat conveyor or turntable unscrambler. A star wheel grips vials precisely under the nozzles; a “no vial, no fill” sensor prevents errors.

Stoppering and Sealing: Integrated rubber stoppering station delivers two vials at a time to a vacuum or mechanical plugger, followed by optional aluminum cap crimping for secure closure.

Construction: Full SS 316 construction with polished interiors for easy cleaning and validation. Includes a compact control panel for stroke length adjustment to vary fill volumes.

Safety and Compliance: cGMP, FDA, and CE certified; features like laminar airflow compatibility, HEPA filtration integration, and isolator/RABS enclosure options for aseptic processing.

FAQ for Eight Syringe Vial Filler

What is the production capacity of the Eight Syringe Vial Filler?

The Eight Syringe Vial Filler is designed for high-speed pharmaceutical production, delivering an output of up to 150 vials per minute (approximately 2,400 to 4,000 vials per hour). The exact production rate depends on the vial diameter, liquid viscosity, and the specific fill volume.

What fill volumes and vial sizes can this machine accommodate?

This machine is highly versatile and can be used for a wide range of container sizes and dosages:

Filling Volume: 2 ml to 250 ml.
Vial Diameter: 15 mm to 70 mm.
Vial Height: 25 mm to 140 mm. Volume adjustments are easily managed by increasing or decreasing the stroke length of the pistons.

How does the machine ensure high filling accuracy?

The machine utilizes eight high-precision AISI SS 316L syringes equipped with non-return valves. These valves prevent backflow and volume variation, allowing the machine to maintain a strict filling tolerance of ±0.5% to ±1%.

What mechanisms are in place to prevent product wastage?

To ensure efficient resource management, the machine is equipped with an online “No Vial – No Filling” system. Sensors detect the presence of vials on the conveyor; if a vial is missing at a filling station, the corresponding nozzle will not dispense liquid, keeping the machine clean and preventing the loss of expensive formulations.

Does the machine meet international pharmaceutical standards?

Yes, the Eight Syringe Vial Filler is built for cGMP-compliant environments. All contact parts are made from Stainless Steel 316L, and the main framework is constructed from Stainless Steel 304. It is also designed for easy validation and can be provided with IQ/OQ documentation to support regulatory requirements in the biotech and pharmaceutical industries.

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