Aseptic Bottle Filler and Capper

Q: What are the key features of the Aseptic Bottle Filler and Capper?

High Accuracy : Filling accuracy of ±0.5% to ±1% with piston or peristaltic pumps. Sterile Design : All product contact parts in Stainless Steel 316L, framework in SS 304. Safety Systems : “No Vial – No Filling” and “No Vial – Machine Stop” mechanisms. Automation : Variable AC frequency drive, digital vial counter, in-feed unscrambler, and optional PLC with HMI. Compliance : Easy validation, IQ/OQ documentation, and no cross-contamination for small to large batch production.

Q: What are the main advantages of an Aseptic Bottle Filler and Capper?

Extended Shelf Life : Maintains sterility without preservatives or high-heat processing. Product Safety & Quality : Prevents microbial contamination and preserves sensitive formulations. Efficiency : High-speed automation reduces labor, waste, and operational costs. Versatility : Handles 2ml to 250ml volumes with quick changeovers and various bottle sizes. Regulatory Compliance : Meets GMP, FDA, and other standards with full traceability and validation support.

Description

Aseptic Bottle Filler and Capper is a specialized machine used in the food, beverage, pharmaceutical, and cosmetic industries to fill and seal containers with liquid products under sterile conditions, ensuring a long shelf life without preservatives. These systems maintain a sterile environment to prevent microbial contamination, making them ideal for sensitive products like juices, dairy, sauces, and sterile medications.

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Salient Features of Aseptic Bottle Filler and Capper

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

Digital Vial Counter for counting production output.
In-feed Turn Table/ Unscrambler for automatic feeding of objects.
On-line Mechanism.
“No Vial – No Filling” System.
“No Vial – Machine Stop” System.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Aseptic Liquid Filling Machine

The incoming dry vial (sterilized & siliconised) 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 which are used for liquid filling. The syringes are made of Stainless Steel 316L construction and both, glass as well as Stainless Steel syringes can be used. 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 either increased or decreased 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 will reach to filling nozzles through silicon transparent pipe. Nozzle will be having Up and Down movement with help of cam mechanism and it will come down when vial will be hold by starwheel for filling operation and starts filling when it starts to move up and after completion of filling operation, starwheel delivers six vials together on conveyor for rubber stoppering operation. Stoppering unit consist of Starwheel, Vibrator unit and Bowl. The sterilized and siliconised 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 will pick up the rubber stopper from the exit end of the chute and rubber stopper will be 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 Aseptic Bottle Filler and Capper

Model	ALVF-40	ALVF-80	ALVF-120	ALVF – 250
Filling Heads	Two	Four	Eight	Twelve
Production Rate	Up to 40 Vials/Minute	Up to 80 Vials/Minute	Up to 150 Vials/Minute	Up to 250 Vials/Minute
Vial Diameter	15mm to 70mm	15mm to 70mm	15mm to 70mm	15mm to 70mm
Vial Height	25mm to 140mm	25mm to 140mm	25mm to 140mm	25mm to 140mm
Filling Precision	±1%	±1%	±1%	±1%
Power Required	1 H.P.	1.5 H.P.	2 H.P.	2 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2050mm (L) x 850mm (W) x 1700mm (H)	2200mm (L) x 850mm (W) x 1700mm (H)	3000mm (L) x 945mm (W) x 1700mm (H)	3500mm (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 Bottle Filling Machine

Automatic Bottle Filling Machine

Digital Liquid Filling Machine

Semi Automatic Liquid Filling Machine

Automatic Eye Drop Filling Machine

Motion Liquid Filling Machine

Monoblock Liquid Filling & Capping Machine

Aseptic Liquid Filling Machine

Servo Driven Liquid Filling Machine

Applications of Bottle Filling Machine

Advantages of Aseptic Bottle Filler and Capper

Extends shelf life without preservatives, maintaining product quality.

Reduces material and energy costs compared to hot-fill.

Supports diverse bottle sizes and materials.

High efficiency and automation lower labor costs and improve output.

Key Features of Aseptic Bottle Filler and Capper

Sterilization:
- Containers and Caps: Bottles and caps are sterilized using methods like hydrogen peroxide (H2O2), peracetic acid (PAA), UV radiation, or electron-beam technology. This ensures a high sterilization efficiency, often achieving a 5-6 log reduction in microorganisms.
- Aseptic Chamber: The filling and capping process occurs in a sterile zone, often within a microbiological isolator, maintained with sterile air flow or steam barriers to eliminate contamination risks.

Filling:
- Methods: Filling is typically volumetric or by weight, ensuring precise product volumes. Non-contact filling is common for liquids to avoid contamination, with flow rates adjusted to minimize foaming.
- Temperature: Aseptic filling often occurs at room temperature, preserving product quality compared to hot-fill methods. This also allows for lighter, more flexible bottle designs, reducing material costs.
- Versatility: Handles various liquids, including high- and low-acid beverages, dairy, sauces, and pharmaceuticals, with some systems supporting particles or viscous products.

Capping:
- Caps are pre-sterilized and applied in the aseptic zone. The capper design isolates mechanical parts to prevent contamination, using heat barriers, diaphragms, or non-lubricated materials.
- Servo-driven cappers or automated systems ensure precise torque for secure sealing, with some machines offering tool-less changeovers for different cap types.

System Design:
- Compact and Modular: Modern systems, like combi-block machines, integrate bottle blowing, filling, and capping, reducing space and costs. Outputs range from 6,000 to 48,000 bottles/hour (based on 500ml-1L bottles).
- Hygienic Design: Stainless steel construction with CIP/SIP modules ensures easy cleaning and maintenance.
- Traceability: Systems record sterilization and production parameters for full traceability, meeting strict regulatory standards.

FAQ for Aseptic Bottle Filler and Capper

What is an Aseptic Bottle Filler and Capper?

An Aseptic Bottle Filler and Capper is a specialized sterile packaging machine that fills and seals bottles or vials with liquid products under contamination-free conditions. It maintains a sterile environment throughout the process using advanced sterilization methods, making it ideal for extending shelf life without preservatives. This machine is widely used for sensitive products like juices, dairy, sauces, sterile pharmaceuticals, and injectables in regulated industries.

What are the key features of the Aseptic Bottle Filler and Capper?

High Accuracy: Filling accuracy of ±0.5% to ±1% with piston or peristaltic pumps.
Sterile Design: All product contact parts in Stainless Steel 316L, framework in SS 304.
Safety Systems: “No Vial – No Filling” and “No Vial – Machine Stop” mechanisms.
Automation: Variable AC frequency drive, digital vial counter, in-feed unscrambler, and optional PLC with HMI.
Compliance: Easy validation, IQ/OQ documentation, and no cross-contamination for small to large batch production.

How does the Aseptic Bottle Filler and Capper work?

Sterilized vials/bottles are fed via an unscrambler onto a conveyor belt. They are positioned under filling nozzles (SS 316L syringes) where precise volumetric filling occurs. A star wheel holds the container during filling with a “No Vial-No Filling” sensor. After filling, the machine automatically places and presses sterilized rubber stoppers or caps in a sterile zone. The entire process uses unidirectional airflow and occurs at room temperature to preserve product quality.

What are the main advantages of an Aseptic Bottle Filler and Capper?

Extended Shelf Life: Maintains sterility without preservatives or high-heat processing.
Product Safety & Quality: Prevents microbial contamination and preserves sensitive formulations.
Efficiency: High-speed automation reduces labor, waste, and operational costs.
Versatility: Handles 2ml to 250ml volumes with quick changeovers and various bottle sizes.
Regulatory Compliance: Meets GMP, FDA, and other standards with full traceability and validation support.

Which industries and products is the Aseptic Bottle Filler and Capper suitable for?

It is primarily used in the Pharmaceutical, Biotech, Food & Beverage, Cosmetic, and Chemical industries. The machine excels with sterile liquids, injectables, dairy products, juices, sauces, and other sensitive or high-value liquids in vials and bottles ranging from 15mm to 70mm diameter and 25mm to 140mm height.

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