Automatic Vial Cap Sealing Machine

Q: What is an Automatic Vial Cap Sealing Machine used for?

An Automatic Vial Cap Sealing Machine is specifically designed to seal injectable glass vials with aluminum or flip-off caps . It is a critical component in pharmaceutical, veterinary, and biotech production lines, ensuring a hermetic seal that maintains sterility and drug stability in compliance with cGMP standards .

Q: How does the machine ensure consistent sealing without damaging the vials?

The machine utilizes spring-loaded, free-spinning sealing rollers . This mechanism applies controlled, gradual pressure to the cap during rotation, accommodating minor variations in the vial neck diameter while eliminating the risk of cracking the glass or damaging the aluminum seals.

Description

Automatic Vial Cap Sealing Machine are specialized equipment designed for sealing injectable glass vials with aluminum or flip-off caps, widely used in the pharmaceutical, veterinary, and biotech industries. These machines ensure a hermetic seal to maintain container closure integrity, sterility, and drug stability, adhering to Current Good Manufacturing Practices (cGMP) standards. These machines can be integrated into complete sterile Vial Filling Lines, connecting with Vial Filling and Labeling Machines for seamless operation. Monoblock Systems Combine Filling, Stoppering, and Capping in a single platform for enhanced efficiency.

Vial Feeding: Stoppered vials are fed from a filling machine via a conveyor belt to an infeed starwheel, which ensures proper spacing and alignment.

Cap Placement: Aluminum or flip-off caps are automatically oriented in a vibratory bowl and delivered via a chute. Vials pick up caps as they move under the cap feed.

Sealing: The sealing head applies controlled pressure and rotation to crimp or thread the cap, forming a secure, hermetic seal. Single spinning rollers or GPS systems ensure precision.

Discharge: Sealed vials are indexed by the starwheel to an outfeed conveyor or collection tray, ready for further processing.

If you need details on specific models, pricing, or comparisons with multi-head machines, let me know!

Salient Features of Automatic Vial Cap Sealing Machine

Single motor synchronises conveyor, starwheels and platform turret and speed can be varied by the speed pot on operating panel.
Parts coming in contact with the vial / aluminium cap / exposed to the atmosphere are made out of stainless steel for good house keeping & GMP accordance.
Spring loaded free spinning sealing rollers eliminates any damage to aluminiumcaps and also allows greater flexibility of variation in the container neck diameter.
Photo sensing device stop machine automatically in the event of no aluminium cap in delivery chute.
Acrylic Cabinet with Aluminium Structure for Machine. (Optional)
Programmable Logic Control with GUI. (Optional)

A complete cGMP model.
“No Stopper on Vial Before Sealing – Machine Stop” system.
“No Seal in Chute – Machine stop” system.
Sealing Pressure can be varied to suit different gauges and sizes of aluminium caps.
Variable A.C. frequency drive for speed adjustment.
Digital Counter for counting number of sealed vials.
A Special clutch device is incorporated on the infeed worm and Starwheel system for stoppage of machine in the event, vial is over turned or over diameter.

Working Principle of Automatic Vial Cap Sealing Machine

Duly Stoppered vials are continuously fed from the convetor of filling machine to the flat conveyor belt of sealing machine and move further through infeed worm for correct spacing and transferred to the infeed starwheel. Aluminium caps kept in vibratory bowl automatically orient caps in right direction before entering the delivery chute. Vial during its rotation movement with infeed starwheel picks up aluminum seal from the retaining finger of delivery chute and correctly position on the vial before entering sealing turret. Vial now moves on the spring loaded sealing platform, where free spinning sealing rollers moves gradually inside to complete the sealing operation during rotational movement of sealing platform turret. Now sealed vials are transferred to exit starwheel pocket and further moves out on to the flat conveyor belt. Duly sealed vials are collected on out-feed collection tray.

Technical Specification of Automatic Vial Cap Sealing Machine

Model	ACS-60	ACS-120	ACS-200
No. of Sealing Head	Single	Four	Eight
Production Rate	Up to 50 Vials/Minute	Up to 100 Vials/Minute	Up to 200 Vials/Minute
Container Diameter:	15mm to 80mm	15mm to 80mm	15mm to 80mm
Container Height:	20mm to 180mm	20mm to 180mm	20mm to 180mm
Cap Diameter:	13mm, 20mm, 28mm, 30mm & 33mm with the help of change parts.	13mm, 20mm, 28mm, 30mm & 33mm with the help of change parts.	13mm, 20mm, 28mm, 30mm & 33mm with the help of change parts.
Power Supply	0.5 H.P.	1 H.P.	2 H.P.
Electrical characteristics	440 Volts, 3 Phase, 50 Hertz, 4 Wire System	440 Volts, 3 Phase, 50 Hertz, 4 Wire System	440 Volts, 3 Phase, 50 Hertz, 4 Wire System
Optional Accessories	Aluminum profile cabinet covering full machine	Aluminum profile cabinet covering full machine	Aluminum profile cabinet covering full machine
	Chuck for flip-off seal	Chuck for flip-off seal	Chuck for flip-off seal
	PLC with HMI	PLC with HMI	PLC with HMI
Overall Dimension	1300mm X 800mm (W) X 1800mm (H) approx.	1500mm (L) x 850mm (W) x 1800mm (H) approx.	2000mm (L) x 850mm (W) x 1800mm (H) approx.

* 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 Capping and Sealing Machine

Automatic Ropp Screw Capping Machine

Automatic Bottle Screw Capping Machine

Automatic Bottle CRC Capping Machine

Automatic Bottle Lug Capping Machine

Automatic Vial Capping Machine

Automatic Jar Capping Machine

Automatic Linear Bottle Capping Machine

High Speed Vial Cap Sealing Machine

High Speed Bottle Capping Machine

Semi Automatic Bottle Capping Machine

Applications of Capping and Sealing Machine

Benefits of Automatic Vial Cap Sealing Machine

Efficiency: High-speed models maximize throughput, while single-head models suit smaller batches.

Reliability: Robust construction and safety features reduce downtime and ensure consistent performance.

Compliance: Designed for cGMP compliance, with optional IQ/OQ/DQ documentation for regulatory validation.

User-Friendly: Minimal mechanical adjustments, intuitive PLC/HMI controls, and low maintenance requirements enhance ease of use.

Key Components of Automatic Vial Cap Sealing Machine

Versatility and Scalability:
- Available in various configurations, such as single-head, four-head, six-head, eight-head, or twelve-head models, catering to small, medium, and large-scale production needs.
- Capable of handling a wide range of vial sizes and cap types with interchangeable change parts for flexibility.
- High-speed models can achieve outputs of up to 400 vials per minute, depending on the number of sealing heads.

Precision and Quality:
- Equipped with precise sealing mechanisms, such as single spinning rollers or gradual pressure sealing (GPS) systems, to ensure consistent, high-quality seals without damaging vials or caps.
- Adjustable sealing pressure accommodates different cap gauges and sizes, ensuring optimal sealing for various vial types.
- Force measurement systems provide precise control over sealing pressure, enhancing seal integrity.

Automation and Safety:
- Fully automatic operation with features like “No Vial – No Capping” and “No Stopper – Machine Stop” systems to prevent errors and ensure safety.
- Safety clutch devices on infeed worms and starwheel systems stop the machine if vials are overturned or oversized, preventing breakage.
- Photo-sensing devices halt operations if no caps are detected in the delivery chute, minimizing downtime.

Design and Materials:
- Constructed with stainless steel for durability, hygiene, and corrosion resistance, with contact parts designed to meet cGMP and 21 CFR Part 11 compliance.
- Compact, aseptic designs compatible with cleanrooms, laminar airflow hoods, bio-safety cabinets, or isolators, minimizing contamination risks.
- Low-noise, low-power consumption, and self-lubricating components reduce maintenance and operational costs.

Advanced Features:
- Equipped with vibratory bowl feeders for automatic, accurate cap orientation and delivery.
- Variable AC frequency drives and gear motors allow speed adjustments to meet production requirements.
- Optional features include PLC systems with Human Machine Interfaces, digital vial counters, safety cabinets, and laminar airflow for sterile environments.

FAQ for Automatic Vial Cap Sealing Machine

What is an Automatic Vial Cap Sealing Machine used for?

An Automatic Vial Cap Sealing Machine is specifically designed to seal injectable glass vials with aluminum or flip-off caps. It is a critical component in pharmaceutical, veterinary, and biotech production lines, ensuring a hermetic seal that maintains sterility and drug stability in compliance with cGMP standards.

What are the production capacities for different models?

The machine is available in several configurations to match your production scale:

Single Head (ACS-60): Up to 50 vials per minute.
Four Head (ACS-120): Up to 100 vials per minute.
Eight Head (ACS-200): Up to 200 vials per minute.

Which vial and cap sizes is the machine compatible with?

The system is highly versatile and can be adjusted for a wide range of containers:

Vial Diameter: 15mm to 80mm.
Vial Height: 20mm to 180mm.
Cap Diameter: 13mm, 20mm, 28mm, 30mm, and 33mm (using interchangeable change parts).

How does the machine ensure consistent sealing without damaging the vials?

The machine utilizes spring-loaded, free-spinning sealing rollers. This mechanism applies controlled, gradual pressure to the cap during rotation, accommodating minor variations in the vial neck diameter while eliminating the risk of cracking the glass or damaging the aluminum seals.

What automation interlocks are included to prevent errors?

To maintain high-quality control and reduce waste, the machine features several intelligent sensors:

“No Stopper on Vial – Machine Stop”: Prevents unstoppered vials from being sealed.
“No Seal in Chute – Machine Stop”: Automatically halts the machine if the cap supply is exhausted.
Safety Clutch Device: Immediately stops the machine if a vial is overturned or oversized to prevent breakage and downtime.

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