Automatic Vial Sealing Machine

Q: What is the production capacity of the Automatic Vial Sealing Machine?

The machine is available in three models: ACSR-60 (Single Head) : Up to 50 vials per minute ACSR-120 (Four Head) : Up to 100 vials per minute ACSR-200 (Eight Head) : Up to 200 vials per minute Actual output depends on vial size, cap type, and product characteristics.

Description

Automatic Vial Sealing Machine is a specialized piece of equipment designed for the pharmaceutical, biotechnology, and cosmetic industries to automate the process of sealing glass or plastic vials with aluminum caps, flip-off caps, or tear-off caps. These machines ensure secure, sterile, and tamper-evident closures, maintaining the integrity and safety of the vial contents, such as injectable drugs, vaccines, or other sensitive liquids and powders.

The operation of an Automatic Vial Sealing Machine typically involves the following steps:

Vial Feeding: Vials are fed via a conveyor belt, turntable, or unscrambler to the sealing station. Automated feeding systems ensure continuous supply and proper alignment.

Cap Feeding: Aluminum caps are oriented and fed from a vibratory bowl or electromagnetic feeder into a delivery chute for precise placement on vials.

Cap Placement: A starwheel or infeed worm positions the vial under the cap delivery system, where the cap is placed onto the vial.

Sealing/Crimping: Spinning rollers or crimping heads apply controlled pressure to crimp the aluminum cap’s skirt around the vial’s neck, securing the stopper and ensuring a tamper-evident seal.

Discharge: Sealed vials are transferred to an outfeed conveyor or collection tray, with defective units rejected via automated inspection systems.

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

Salient Features of Automatic Vial Sealing Machine

Compact GMP model.
Single motor synchronizes Conveyor, star wheel and Platform Turret and speed can be varied by VFD.
Quick and very easy change over and setting from one size of Container to another by a Single Ratchet.
Parts coming in contact with the Container or the Aluminum cap or exposed to atmosphere are made out of stainless steel for long life.
Quick and very easy change over and setting from one size of Container to another by a Single Ratchet.
Star Wheel is equipped with safety clutch for automatic stoppage of machine in case of jamming or overloading.
Various safety features including Clutch system to avoid Bottle Breakage or Jamming

“Container Overturn – Machine Stop” mechanism.
“No Bottle – No Cap” system.
PLC system with Graphical User Interface can be offered.
Digital counter for counting production output.
Machine construction in Stainless Steel Finish
Cap Feeder with Variable Speed System for feeding control of caps. (optional)
Hopper can be completely dismantling for easy cleaning
IQ/OQ documentation can be provided.

Working Principle of Automatic Vial Sealing Machine

The filled bottles moving on conveyor belt and fed into an in feed star wheel by in-feed worm. While moving in feed star wheel, bottles pick up caps one by one from delivery chute. The descending rotary sealing heads hold bottle’s neck with desired pressure. The sealing is done in a programmed roll-on manner, accurate positioned of the caps is done mechanically by means of a rotating unscramble, to direct the caps correctly into the chute, when the chute is filled up the rotating unscramble drive is disengaged, hence, there is no chance to damage of caps. The sealing roller takes place due to rotating sealing head and transfer movement of sealing & threading rollers due to sealing cam. The sealed bottles are discharged by exist star wheel on conveyors.

Technical Specification of Automatic Vial Sealing Machine

Model	ACSR-60	ACSR-120	ACSR-200
No. of Capping Heads	Single	Four	Eight
Production Rate	Up to 50 Containers/Minute	Up to 100 Containers/Minute	Up to 200 Containers/Minute
Container Diameter:	24mm to 90mm	24mm to 90mm	24mm to 90mm
Container Height:	50mm to 250mm	50mm to 250mm	50mm to 250mm
Cap Diameter:	20mm, 25mm & 28mm with the help of change parts	20mm, 25mm & 28mm with the help of change parts	20mm, 25mm & 28mm with the help of change parts
Power Specification:	1 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
Conveyor Height	800mm to 900mm adjustable	800mm to 900mm adjustable	800mm to 900mm adjustable
Optional Accessories	Safety Cabinet Covering Machine	Safety Cabinet Covering Machine	Safety Cabinet Covering Machine
–	PLC with HMI	PLC with HMI	PLC with HMI
Overall Dimension	1500mm (L) X 850mm (W) X 1800mm (H) approx.	1675 (L) x 1000mm (W) x 1800mm (H) approx.	2000 (L) x 1000mm (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

Advantages of Automatic Vial Sealing Machine

High Throughput: Speeds up to 13,000 vials per hour for high-volume production.

Consistency: Ensures uniform sealing quality, reducing the risk of contamination or leakage.

Cost-Effective: Automation reduces labor costs and increases production efficiency.

Regulatory Compliance: Meets stringent cGMP and sterility requirements, critical for pharmaceutical applications.

Flexibility: Customizable for different vial sizes, cap types, and production needs.

Key Features of Automatic Vial Sealing Machine

Automation and Efficiency:
- Fully or semi-automatic operation, capable of handling high-volume production with speeds ranging from 30 to 400 vials per minute, depending on the model.
- Equipped with automated vial feeding, cap placement, and sealing processes, reducing manual intervention and labor costs.
- Integration with upstream and downstream equipment for seamless production lines.

Precision and Quality:
- Uses spinning rollers or crimping mechanisms to securely seal aluminum caps, ensuring consistent pressure and preventing damage to vials or caps.
- Adjustable sealing pressure to accommodate various vial sizes and cap types.
- Incorporates safety features like “No Vial – No Capping” and “No Stopper – No Sealing” systems to prevent errors and ensure proper sealing.
- Force measurement systems for precise control over sealing pressure, ensuring optimal stopper compression and container closure integrity (CCI).

cGMP Compliance and Sterility:
- Designed to meet Current Good Manufacturing Practices (cGMP) and 21 CFR Part 11 standards for pharmaceutical production.
- Constructed with high-quality materials, such as AISI 304 or 316L stainless steel for parts in contact with vials or caps, ensuring corrosion resistance and hygiene.
- Compatible with cleanrooms, laminar airflow hoods, bio-safety cabinets, and aseptic isolators to maintain sterile conditions.

Versatility:
- Handles a wide range of vial sizes and cap types with customizable change parts.
- Suitable for sealing glass or plastic vials used in pharmaceuticals, cosmetics, and other industries.

Advanced Control Systems:
- Equipped with Programmable Logic Controllers (PLC) and Human-Machine Interfaces (HMI) for easy operation, real-time monitoring, and parameter adjustments.
- Optional features like digital counters for tracking sealed vials, photo-sensing devices for error detection, and SCADA systems for data logging.
- Customizable panel language and user-friendly interfaces for operator convenience.

Safety and Maintenance:
- Features safety mechanisms like clutch devices on infeed worms and starwheels to stop the machine if a vial is overturned or jammed.
- Spring-loaded sealing rollers to prevent damage to caps and allow flexibility for varying neck diameters.
- Easy-to-clean design with minimal maintenance requirements, often including non-toxic, synthetic rubber tubing and accessible components.

Optional Features:
- Acrylic cabinets or laminar airflow systems for enhanced sterility.
- Integration with inspection systems.
- Explosion-proof designs for handling volatile substances in powder filling applications.

FAQ for Automatic Vial Sealing Machine

What is an Automatic Vial Sealing Machine?

The Automatic Vial Sealing Machine is a fully automatic rotary machine designed to seal aluminum caps (including plain, flip-off, and tear-off caps) on glass or plastic vials. It is widely used in the pharmaceutical, biotech, and cosmetic industries for sealing injectable products, vaccines, antibiotics, and sterile liquids. Available in Single Head, Four Head, and Eight Head models, it ensures precise, consistent, and leak-proof sealing while meeting cGMP standards.

What is the production capacity of the Automatic Vial Sealing Machine?

The machine is available in three models:

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

Actual output depends on vial size, cap type, and product characteristics.

What vial and cap sizes can the machine handle?

The Automatic Vial Sealing Machine supports a wide range of formats:

Vial Diameter: 24 mm to 90 mm
Vial Height: 50 mm to 250 mm
Cap Sizes: 20 mm, 25 mm, and 28 mm (with change parts)

It can handle aluminum caps, flip-off caps, and tear-off caps on both molded and tubular glass vials.

What safety features does the Automatic Vial Sealing Machine include?

The machine is equipped with multiple safety interlocks for safe and reliable operation:

No Vial – No Cap system
Container Overturn – Machine Stop
Safety clutch mechanism in the star wheel to prevent jamming and vial breakage
Overload protection

These features minimize product wastage and ensure operator safety.

What are the key benefits and optional features?

Key benefits include high-speed operation, quick size changeover with a single ratchet, precise sealing, low maintenance, easy cleaning, and consistent hermetic sealing. Optional features include:

PLC with HMI and touchscreen
Laminar Air Flow (LAF) unit
Full safety cabinet enclosure
Variable speed cap feeder
Digital production counter
IQ/OQ documentation

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