Sterile Liquid Filling Machine

Q: What models, capacities, and filling ranges are available?

The machine is available in four main models: ALVF-40 : 2 filling heads, up to 40 vials/min ALVF-80 : 4 filling heads, up to 80 vials/min ALVF-120 : 8 filling heads, up to 150 vials/min ALVF-250 : 12 filling heads, up to 250 vials/min Filling range : 2 ml to 250 ml with ±1% filling accuracy . It handles vial diameters of 15–70 mm and heights of 25–140 mm.

Q: What are the key features that ensure sterility and performance?

Key features include: Piston or Peristaltic pump aseptic filling with SS 316L syringes and contact parts (framework in SS 304). “No Vial – No Filling” and “No Vial – Machine Stop” systems. Minimal distance between filling and stoppering to reduce contamination risk. Variable AC frequency drive, digital vial counter, in-feed turntable/unscrambler, and easy validation for small/large batches. Optional PLC with GUI and IQ/OQ documentation.

Q: Which industries use this machine and what are the main benefits?

It is primarily used in the Pharmaceutical, Biotechnology, Cosmetic , and Veterinary industries. Main benefits include: High sterility assurance with no cross-contamination. Precision & efficiency — ±1% accuracy and high output (up to 250 vials/min). Hygiene & compliance — SS 316L contact parts and cGMP design. Flexibility — Easy changeover, validation, and integration into sterile lines. Reduced product waste and labor costs.

Description

Sterile Liquid Filling Machine is specialized equipment designed to fill containers such as vials, bottles, syringes, or cartridges with liquid products under strict aseptic conditions to prevent contamination, primarily used in the pharmaceutical, biotechnology, and cosmetics industries. These machines ensure precision, hygiene, and compliance with stringent regulatory standards like cGMP and FDA requirements.

Container Feeding: Containers are fed via a conveyor belt or turntable to the filling station.

Positioning: Containers are aligned under filling nozzles for precise dispensing.

Filling: Liquid is pumped from a reservoir into containers using volumetric or peristaltic systems, with parameters like speed, temperature, and pressure adjusted for liquid viscosity.

Stoppering/Capping: Post-filling, containers are sealed with rubber stoppers or caps, often under vacuum or sterile air overpressure to maintain sterility.

Sterility Maintenance: The minimal distance between filling and stoppering units reduces contamination risks, and the unscrambler design eliminates hard-to-clean areas.

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Salient Features of Sterile Liquid Filling Machine

Suitable for the filling Volume of 2ml to 250ml.
Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±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 Sterile Liquid Filling Machine

Bottles are feed on to in-built Infeed turn table, from where it delivered to SS conveyor belt. Conveyor belt transport bottles to filling station. Filling station has Pneumatic bottle stopper for exact bottle neck centering of bottles during filling operation.

Nozzle goes upwards slowly from the bottom level of bottle towards neck during filling to minimize forming adjustable nozzle is reciprocating according to filling dose.

The dosing block with a hexagonal bolt, this means different fill size can be set easily within minimum use of time.

After liquid filling bottles are delivered to capping/labeling machine conveyor for further operations.

Container Feeding: Containers are fed via a conveyor belt or turntable to the filling station.

Positioning: Containers are aligned under filling nozzles for precise dispensing.

Filling: Liquid is pumped from a reservoir into containers using volumetric or peristaltic systems, with parameters like speed, temperature, and pressure adjusted for liquid viscosity.

Stoppering/Capping: Post-filling, containers are sealed with rubber stoppers or caps, often under vacuum or sterile air overpressure to maintain sterility.

Sterility Maintenance: The minimal distance between filling and stoppering units reduces contamination risks, and the unscrambler design eliminates hard-to-clean areas.

Technical Specification of Sterile Liquid Filling Machine

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 Sterile Liquid Filling Machine

Hygiene and Safety: Ensures sterile filling to prevent microbial contamination, critical for injectables and sensitive products.

Precision and Consistency: Delivers accurate dosing, reducing waste and ensuring uniform product quality.

Efficiency: Automates filling, increasing throughput and reducing labor costs, especially in high-speed monobloc systems.

Versatility: Handles various container types and liquid viscosities, with tool-less changeovers for flexibility.

Regulatory Compliance: Meets cGMP, FDA, and other standards for sterile processing.

Key Features of Sterile Liquid Filling Machine

Aseptic Design: Operates in sterile environments, often under laminar flow protection or within isolators/RABS to maintain sterility and minimize contamination risks.

Material and Construction: Typically made with stainless steel 316L for contact parts and stainless steel 304 for frameworks, ensuring durability, corrosion resistance, and ease of cleaning. Non-toxic synthetic rubber tubing is used to avoid contamination.

Filling Mechanisms: Utilizes precise dosing systems such as piston pumps, peristaltic pumps, or rolling diaphragm pumps for accurate filling of liquids ranging from low to high viscosity. Filling accuracy is typically ±0.5% to ±1%.

Volume Range: Can handle a wide range of fill volumes, typically from 2ml to 250ml for vials, with some machines capable of filling up to 1000ml.

Automation Levels: Available in manual, semi-automatic, and fully automatic configurations:
- Manual: Suitable for small-scale or lab use, operated by hand with no automation.
- Semi-Automatic: Combines manual container loading with automated filling for small-to-medium batches.
- Fully Automatic: Features conveyor systems, inline filling, and stoppering/capping for high-speed production.

Sterilization and Cleaning: Equipped with Cleaning-in-Place (CIP) or Sterilization-in-Place (SIP) systems to maintain hygiene between batches. Some use single-use assemblies to eliminate cross-contamination risks.

Containment Systems: Incorporates isolators, LAF, or RABS for operator and product safety, especially for potent or toxic substances.

High-Speed Capability: Advanced models like monobloc systems integrate filling, stoppering, capping, and labeling in one unit, ideal for large-scale production with outputs up to 15,000 bottles per hour.

Checkweighing: Some machines include load cells to verify fill accuracy by measuring tare and gross weights, ensuring compliance with strict standards.

FAQ for Sterile Liquid Filling Machine

What is a Sterile Liquid Filling Machine and why is it used?

A Sterile Liquid Filling Machine is specialized equipment designed to fill vials, bottles, syringes, or cartridges with liquid products under strict aseptic/sterile conditions. It prevents microbial contamination during the filling and stoppering process, making it essential for pharmaceuticals (injectables, vaccines), biotechnology, and high-end cosmetics. The machine operates in a sterile area under laminar flow protection and complies with cGMP and FDA standards.

What models, capacities, and filling ranges are available?

The machine is available in four main models:

ALVF-40: 2 filling heads, up to 40 vials/min
ALVF-80: 4 filling heads, up to 80 vials/min
ALVF-120: 8 filling heads, up to 150 vials/min
ALVF-250: 12 filling heads, up to 250 vials/min

Filling range: 2 ml to 250 ml with ±1% filling accuracy. It handles vial diameters of 15–70 mm and heights of 25–140 mm.

What are the key features that ensure sterility and performance?

Key features include:

Piston or Peristaltic pump aseptic filling with SS 316L syringes and contact parts (framework in SS 304).
“No Vial – No Filling” and “No Vial – Machine Stop” systems.
Minimal distance between filling and stoppering to reduce contamination risk.
Variable AC frequency drive, digital vial counter, in-feed turntable/unscrambler, and easy validation for small/large batches.
Optional PLC with GUI and IQ/OQ documentation.

How does the Sterile Liquid Filling Machine work?

Vials are fed via an infeed turntable onto the SS conveyor belt. A pneumatic stopper centers each vial under the filling nozzles. The nozzles descend and move upward during filling (reciprocating motion) to minimize foaming. Precise dosing is achieved via the adjustable dosing block. After filling, vials proceed to the stoppering unit (often with pre- and post-gassing) and then to capping or labeling. The entire process maintains sterility under laminar airflow.

Which industries use this machine and what are the main benefits?

It is primarily used in the Pharmaceutical, Biotechnology, Cosmetic, and Veterinary industries. Main benefits include:

High sterility assurance with no cross-contamination.
Precision & efficiency — ±1% accuracy and high output (up to 250 vials/min).
Hygiene & compliance — SS 316L contact parts and cGMP design.
Flexibility — Easy changeover, validation, and integration into sterile lines.
Reduced product waste and labor costs.

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