Four Head Vial Cap Sealing Machine

A Four Head Vial Cap Sealing Machine is an automated pharmaceutical machine designed for sealing injectable glass vials with aluminum caps, including plain aluminum seals and flip-off caps. It is suitable for medium-scale production in the pharmaceutical, veterinary, and biotech industries, offering high efficiency, precision, and compliance with Good Manufacturing Practices (GMP).

Vial Cap Sealing Machine Video

Key Features

1. Construction and Materials:

   • Built with a sturdy stainless steel frame for durability and GMP compliance.

   • Parts in contact with vials, aluminum caps, or exposed to the environment are made of AISI 304 stainless steel, ensuring hygiene and minimal particle generation.

   • Optional acrylic cabinet with aluminum structure for enhanced cleanliness and safety.

2. Sealing Mechanism:

   • Utilizes a unique single roller sealing system with spring-loaded free-spinning rollers to ensure wrinkle-free, hermetic sealing of vials.

   • Gradual Pressure Sealing (GPS) system applies controlled pressure to achieve high-quality seals without damaging caps or vials.

   • Adjustable sealing pressure accommodates various cap sizes and gauges, including PP/flip-off and tear-off caps.

3. Output Capacity:

   • Capable of sealing up to 120 vials per minute, depending on vial diameter, height, and cap size.

   • Higher throughput compared to single-head machines, making it ideal for medium-scale production.

4. Automation and Control:

   • Equipped with a variable AC frequency drive and gear motor, allowing operators to adjust speed based on production needs.

   • Optional PLC system with Human Machine Interface (HMI) for advanced control and automation, compliant with 21 CFR Part 11 regulations.

   • Digital counter for tracking the number of sealed vials.

5. Safety and Error Prevention:

   • No Stopper, No Sealing System: Automatically stops the machine if a vial lacks a rubber stopper, preventing improper sealing.

   • No Cap, Machine Stop: A photo-sensing device halts the machine if no aluminum cap is detected in the delivery chute.

   • Safety Clutch Device: Incorporated in the infeed worm and starwheel to stop the machine if a vial is overturned or oversized, preventing jams or breakage.

6. Cap Feeding System:

   • Features a vibratory bowl feeder that automatically orients aluminum caps in the correct direction before feeding them into the delivery chute.

   • Caps are picked up by vials during rotation in the infeed starwheel and positioned accurately before sealing.

7. Vial Handling:

   • Compatible with molded or tubular glass vials ranging from 2 ml to 100 ml.

   • Infeed worm ensures proper spacing between vials, transferring them to the infeed starwheel for precise positioning under the sealing heads.

   • Spring-loaded sealing platform accommodates variations in vial neck diameter for flexible operation.

8. Optional Features:

   • Safety cabinet with doors for closed operation.

   • Laminar Air Flow system for sterile Class 100 environments.

   • IQ/OQ/DQ validation documentation for regulatory compliance.

Operation Workflow

1. Vial Infeed: Stoppered vials are fed from a filling machine’s turntable or conveyor onto the flat conveyor belt of the sealing machine. An infeed worm ensures correct spacing and transfers vials to the infeed starwheel.

2. Cap Placement: Aluminum caps in the vibratory bowl are oriented and fed into the delivery chute. As vials rotate in the infeed starwheel, they pick up a cap from the chute’s retaining finger and position it correctly.

3. Sealing Process: Vials move onto a spring-loaded sealing platform. Four free-spinning sealing rollers gradually apply pressure during the rotational movement of the sealing turret, threading and sealing the cap securely.

4. Output: Sealed vials are transferred to the exit starwheel and move onto the outfeed conveyor belt or collection tray.

Applications

• Primarily used in the pharmaceutical industry for sealing injectable liquid or powder vials.

• Suitable for veterinary and biotech industries requiring sterile, high-precision capping.

• Can be integrated with vial filling and labeling machines to form a complete Sterile Vial Filling Line.

Advantages

• High-speed operation with reliable, hermetic sealing for product integrity.

• Compact design with rotary motion for efficient use of space.

• Flexible for various vial and cap sizes with minimal changeover time using common change parts.

• Safety features reduce downtime and ensure operator safety.

• GMP-compliant design with low particle generation, ideal for sterile environments.

Conclusion

The Four Head Vial Cap Sealing Machine is a high-performance, GMP-compliant solution for medium-scale pharmaceutical production. Its robust construction, advanced automation, and safety features ensure efficient and reliable sealing of vials, making it a critical component in sterile vial filling lines.

Types of Vial Cap Sealing Machine

• Single Head Vial Cap Sealing Machine
• Four Head Vial Cap Sealing Machine
• Eight Head Vial Cap Sealing Machine
• High Speed Vial Cap Sealing Machine
• Automatic Vial Capper Machine

Salient Features of Four Head Vial Cap Sealing Machine

• Complete GMP model.

• “No Stopper on Vial before Sealing – No Sealing” system.

• Digital Counter for counting number of sealed vials

• Single motor synchronizes conveyor, starwheels & platform turret and speed can be varied by the speed pot on operating panel.

• A Special clutch device is incorporated on the infeed worm and Starwheel.

• Spring loaded free spinning sealing rollers eliminates any damage to aluminium caps and also allows greater flexibility of variation in the container neck diameter.

• Parts coming in contact with the vial/aluminium cap or exposed to the atmosphere are made out of stainless steel for good house keeping and good manufacturing practice

• Sealing Pressure can be varied to suit different gauges and sizes of aluminium caps.

• Imported Gear Motor for Main drive.

• Variable A.C. frequency drive for speed adjustment.

Process Operation of  Vial Cap Sealer Machine

Duly Stoppered Vials are continuously fed from the turntable/conveyor 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 are kept in vibratory bowl automatically oriented in right direction before entering the delivery chute. Vial during its rotation movement with infeed starwheel, it picks up aluminum seal from the retaining finger of delivery chute & correctly position on the vial before entering sealing turret. Vials 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 & further moves out on to the flat conveyor belt for further labeling operations.

Technical Specification of Four Head Vial Capping 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.