Automatic Vial Capping Machine

An Automatic Vial Capping Machine is a specialized piece of equipment designed to automate the process of sealing vials with caps, widely used in industries such as pharmaceuticals, biotechnology, cosmetics, and chemicals. These machines enhance productivity, ensure consistent sealing quality, and maintain sterility while reducing manual labor and occupational health risks like repetitive strain injuries.

Automatic Vial Capping Machine Video

Key Features and Components:

1. Automation and Workflow:

   • Fully Automated Process: Handles vial feeding, cap placement, and sealing without manual intervention. Some models integrate additional functions like filling, stoppering, and labeling for a complete production line.

   • Cap Feeding System: Utilizes vibratory bowls, electromagnetic feeders, or gravity-fed systems to orient and deliver caps accurately to the capping station.

   • Sealing Mechanism: Employs spinning rollers, chuck cappers, or crimping heads to apply precise torque or force, ensuring secure and leak-proof seals. Common cap types include screw caps, aluminum crimp caps, flip-off caps, and snap-on caps.

   • Vial Transport: Uses starwheels, conveyors, or robotic arms for precise vial positioning and movement through the capping process.

2. Performance Specifications:

   • Speed: Varies by model, ranging from 10–20 vials per minute for benchtop models to high-speed machines capable of 10,000–13,000 bottles per hour.

   • Cap and Vial Compatibility: Accommodates various vial sizes and cap types. Machines can often be customized for specific sizes.

   • Precision: Advanced control systems ensure consistent torque or crimping force, reducing leakage risks during transportation. Filling accuracy in integrated systems can reach ±0.5–1%.

3. Design and Compliance:

   • Material: Typically constructed with GMP-compliant materials like 304 or 316 stainless steel for corrosion resistance and easy cleaning.

   • Sterility and Contamination Control: Designed for aseptic environments, often compatible with cleanrooms, laminar airflow hoods, or isolators. Some models feature contamination prevention mechanisms like sealed vial movement from below or particle monitoring.

   • Compact and User-Friendly: Benchtop models have a small footprint and require minimal training. High-speed models are modular for easy integration into production lines.

4. Advanced Features:

   • Intelligent Control: Equipped with PLC systems, touch-screen interfaces, and fault detection to monitor and adjust speed, pressure, and torque in real-time. Some models support multiple languages and data tracking for process optimization.

   • Safety and Ergonomics: Reduces operator fatigue and risks like carpal tunnel syndrome by automating repetitive tasks. Safety features include automatic stop for missing caps or overturned vials.

   • Customization: Modular designs allow for add-ons like labeling, inspection, or freeze-drying capabilities. Machines can be tailored to specific production needs, such as high-throughput or small-batch processing.

5. Applications:

   • Primarily used in pharmaceuticals for sealing injectable vials, diagnostic samples, or reagents. Also applicable in cosmetics, food and beverage, and chemical industries.

Considerations:

• Setup Requirements: Some machines require calibration with sample caps and vials.

• Maintenance: Regular cleaning and lubrication are needed to maintain performance and comply with GMP standards.

Automatic vial capping machines are critical for scaling production while ensuring precision, sterility, and efficiency in high-stakes industries.

Salient Features of Automatic Vial Capping Machine

• A complete cGMP model.

• “No Stopper on Vial Before Sealing – Machine Stop” system.

• “No Seal in Chute – Machine stop” system.

• 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.

• 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.

• Photo sensing device stop machine automatically in the event of no aluminium cap in delivery chute.

• 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.

• Acrylic Cabinet with Aluminium Structure for Machine. (Optional)

• Programmable Logic Control with GUI. (Optional)

Process Operation of Automatic Vial Capping 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 Capper Machine

* 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.