Aseptic Filler and Capper

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

Filling Range : 2ml to 250ml with piston or peristaltic pumps. High Accuracy : ±0.5% to ±1% filling precision. Sterile Construction : Product contact parts in SS 316L, framework in SS 304. Safety Systems : “No Vial – No Filling” and “No Vial – Machine Stop” mechanisms. Advanced Controls : Variable AC frequency drive, digital vial counter, in-feed unscrambler, optional PLC with HMI, and IQ/OQ documentation. No Cross-Contamination : Designed for easy validation in small to large batch production.

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

Extended Shelf Life : Maintains product stability without preservatives or refrigeration. Superior Safety : Minimizes contamination risks for consumer protection. High Efficiency : Models available up to 250 vials per minute with low waste. Regulatory Compliance : Supports cGMP, FDA standards with full validation. Versatility : Handles various container sizes (15–70mm diameter, 25–140mm height) and product types.

Description

Aseptic Filler and Capper is a specialized machine used in the food, beverage, and pharmaceutical industries to fill and seal containers under aseptic conditions, ensuring the product remains sterile and free from contamination. These systems are critical for producing shelf-stable products like juices, dairy, sauces, or liquid pharmaceuticals without the need for refrigeration or preservatives.

Container Sterilization: Empty containers are cleaned and sterilized using steam, hydrogen peroxide vapor, or other methods.

Product Sterilization: The product is pre-sterilized and kept in sterile holding tanks.

Filling: The sterile product is dispensed into the sterilized containers in a controlled, aseptic environment.

Capping: Sterilized caps or closures are applied immediately to seal the container, maintaining the aseptic condition.

Quality Control: Inline sensors and systems monitor fill levels, seal integrity, and sterility to ensure compliance with safety standards.

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Salient Features of Aseptic 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 Filler and Capper

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 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

Benefits of Aseptic Filler and Capper

Extended Shelf Life: Products remain stable without refrigeration or preservatives.

Product Safety: Minimizes risk of contamination, ensuring consumer safety.

Efficiency: High-speed, automated systems reduce labor costs and increase production rates.

Versatility: Suitable for a wide range of products and container types.

Key Features of Aseptic Filler and Capper

Aseptic Filler:
- Function: Fills containers with liquid or semi-liquid products in a sterile environment to prevent microbial contamination.
- Process: The product is sterilized before filling, and the container is also sterilized to maintain sterility.
- Types of Containers: Handles various formats like bottles, cans, pouches, or tetra packs.
- Filling Mechanism: Uses precise volumetric or gravimetric filling systems to ensure accurate fill levels.
- Sterile Environment: Operates in a controlled, sterile chamber or cleanroom to prevent contamination from external microbes or particles.

Capper:
- Function: Seals the filled containers with sterile caps, closures, or lids to maintain the aseptic condition and prevent leakage or spoilage.
- Capping Mechanism: Applies screw caps, snap-on caps, foil seals, or other closures using automated systems like rotary cappers or linear cappers.
- Sterilization: Caps are pre-sterilized before application to ensure no contamination.

Key Features:
- Sterility Assurance: Both the filler and capper operate in a sterile environment, often using HEPA-filtered air or overpressure systems to maintain cleanliness.
- Automation: Fully or semi-automated systems with programmable logic controllers (PLCs) for precision and repeatability.
- Clean-in-Place (CIP) and Sterilize-in-Place (SIP): Systems are designed for easy cleaning and sterilization between production runs to prevent cross-contamination.
- Material Compatibility: Constructed from stainless steel or other food-grade, corrosion-resistant materials to meet hygiene standards.
- High-Speed Operation: Capable of high throughput, ranging from hundreds to thousands of containers per hour, depending on the model.
- Flexibility: Adjustable for different container sizes, shapes, and product viscosities.

FAQ for Aseptic Filler and Capper

What is an Aseptic Filler and Capper?

An Aseptic Filler and Capper is a specialized sterile packaging machine used in the food, beverage, and pharmaceutical industries. It fills and seals containers (vials, bottles) under aseptic conditions to keep products free from microbial contamination. This enables production of shelf-stable items like juices, dairy, sauces, and liquid pharmaceuticals without refrigeration or preservatives.

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

Filling Range: 2ml to 250ml with piston or peristaltic pumps.
High Accuracy: ±0.5% to ±1% filling precision.
Sterile Construction: Product contact parts in SS 316L, framework in SS 304.
Safety Systems: “No Vial – No Filling” and “No Vial – Machine Stop” mechanisms.
Advanced Controls: Variable AC frequency drive, digital vial counter, in-feed unscrambler, optional PLC with HMI, and IQ/OQ documentation.
No Cross-Contamination: Designed for easy validation in small to large batch production.

How does the Aseptic Filler and Capper work?

Sterilized vials are fed via an unscrambler onto a conveyor belt. They are positioned under SS 316L filling nozzles/syringes for precise volumetric filling using a star wheel and “No Vial-No Filling” sensor. After filling, vials move to the stoppering unit where sterilized rubber stoppers are automatically placed and pressed using a vibratory bowl, chute, and spring-loaded roller. The entire process occurs in a controlled sterile environment.

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

Extended Shelf Life: Maintains product stability without preservatives or refrigeration.
Superior Safety: Minimizes contamination risks for consumer protection.
High Efficiency: Models available up to 250 vials per minute with low waste.
Regulatory Compliance: Supports cGMP, FDA standards with full validation.
Versatility: Handles various container sizes (15–70mm diameter, 25–140mm height) and product types.

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

It is ideal for the Pharmaceutical, Biotech, Food & Beverage, Cosmetic, and Chemical industries. The machine excels with sterile injectables, vaccines, dairy products, juices, sauces, and other sensitive liquids in vials and bottles.

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