Twelve Head Vial Cap Sealing Machine

Q: What is the production capacity of the Twelve Head Vial Cap Sealing Machine?

The machine has a high production capacity of 250 to 400 vials per minute , depending on vial size, cap type, and product characteristics. It is one of the fastest models in the range, making it suitable for high-volume pharmaceutical manufacturing lines.

Description

Twelve Head Vial Cap Sealing Machine is a high-speed, Automatic Rotary Capping Machine designed primarily for the pharmaceutical industry. It is used to apply and crimp aluminum flip-off or tear-off caps onto pre-filled and stoppered vials, ensuring a hermetic seal to maintain the sterility and integrity of injectable products. This machine is suitable for large-scale production and can process up to 400 vials per minute, depending on the vial size and cap specifications. It complies with cGMP standards for hygiene and is often integrated into complete vial filling lines, connecting upstream to filling machines and downstream to labeling equipment.

In-Feed: Stoppered vials are fed via a conveyor belt into an in-feed worm and star wheel, which positions them accurately.

Cap Pickup: As the star wheel indexes, vials pass under the cap feed chute, picking up an oriented aluminum cap from the vibratory bowl.

Sealing Station: Vials with caps advance to the twelve-head rotary capping turret. The sealing heads descend, rotate clockwise, and crimp the cap skirt using spinning rollers or chucks, forming a secure thread and hermetic seal.

Out-Feed: The star wheel indexes the sealed vials onto the discharge conveyor, where a counter tracks production. The process is continuous and synchronized for high throughput.

Indexing: The twelve heads enable simultaneous processing of multiple vials per cycle, achieving the high speed of 300–400 vials per minute.

Twelve Head Vial Cap Sealing Machine is versatile for pharmaceutical packaging, minimizing particle generation and ensuring consistent seal quality critical for sterile injectables.

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

Salient Features of Twelve Head Vial Cap Sealing Machine

Compact machine complies as per cGMP.
Photo sensing device stop machine automatically in the event of no aluminium cap in delivery chute. (Optional)
Clutch system provided to stop machine in case of odd diameter of vials hence avoiding vial breakage.
Safety cabinet with doors provided for closed operation. (Optional)
Spring loaded free spinning sealing assembly provide flexibility of variation in the container neck diameter.
Differential Sealing Pressure adjustment option for variation in cap types.
Contact parts of main area made of Stainless Steel or other food grade materials.

Speed control with Variable A.C. frequency drive.
Produced vials counted with inbuilt digital counter.
“No Stopper on Vial – Machine Stop” system.
“No Seal in Chute – equipment stop” feature.
One motor synchronizes key operations of machine.
IQ/OQ/DQ documentation on demand.
PLC system with Human Machine Interface can offer optionally.
Laminar Air Flow can be offered optionally for sterile class 100 filling.

Working Principle of Twelve Head Vial Cap Sealing Machine

Our Automatic Vial Sealing Machine has a conveyor belt that moves the feed container to the star wheel. Now the star wheel sets the container below the sealing head for the indexing bit. Caps are picked by vials from the delivery chute of the cap feeding bowl of the machine. The body and neck of the container are placed below the rotating head of the machine. The sealing head of the machine performs threading and sealing with precision. Designed with stainless steel matt finish, the machine comprises of no container, no cap arrangement.

Adinath International is a leading Twelve Head Vial Capping Machine manufacturer in India with a substantial portfolio. For detailed information about Vial Capping Machines offered by us, feel free to drop us a line.

Technical Specification of Twelve Head Vial Cap Sealing Machine

Model	ACS-400
No. of Sealing Head	Twelve
Production Rate	250 to 400 Vials/Minute
Container Diameter:	15mm to 80mm
Container Height:	20mm to 180mm
Cap Diameter:	13mm, 20mm & 28mm with the help of change parts.
Power Supply	1.5 H.P.
Electrical characteristics	440 Volts, 3 Phase, 50 Hertz, 4 Wire System
Optional Accessories	Aluminum profile cabinet covering full machine
	Chuck for flip-off seal
	PLC with GUI
Overall Dimension	1750mm X 950mm (W) X 1800mm (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 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 Twelve Head Vial Cap Sealing Machine

High Efficiency: Rapid sealing rates reduce production bottlenecks.

Precision and Quality: Ensures leak-proof, contamination-free seals critical for injectable drugs.

Flexibility: Accommodates various vial and cap sizes with minimal changeover time.

Reliability: Robust construction and safety features minimize downtime and vial damage.

Compliance: Meets stringent pharmaceutical standards.

Key Features of Twelve Head Vial Cap Sealing Machine

Construction: Built on a sturdy mild steel frame with stainless steel enclosures and cladding for corrosion resistance and easy cleaning. All parts in contact with vials, caps, or exposed to the atmosphere are made of stainless steel to meet GMP requirements.

Drive System: Synchronized AC variable frequency drives for the conveyor, star wheel, platform turret, and capping bowl, allowing precise speed control and smooth operation.

Safety and Control Features:
- “No Vial – No Capping” system: Prevents cap application if no vial is present, reducing waste.
- “No Stopper – Machine Stop” system: Halts operation if vials lack proper stoppers.
- Safety clutch on the star wheel to stop the machine in case of jams or overturned vials.
- Tower light indicators for machine status.
- Optional vision system for cap and seal quality checking, and in-feed rejection for defective stoppers.

Sealing Mechanism: Spring-loaded, free-spinning sealing rollers or chucks provide gradual pressure sealing for wrinkle-free, crease-free seals. This eliminates damage to caps and accommodates variations in vial neck diameters. Pneumatic sealing heads and Viton rollers are available as options for enhanced performance.

Cap Feeding: Gravity-fed vibratory bowl for accurate, oriented feeding of aluminum caps from a delivery chute.

Noise and Energy Efficiency: Operates with low noise levels and energy consumption, making it suitable for cleanroom environments.

Customization: Adjustable sealing pressure for different cap types. Change parts allow compatibility with various vial and cap sizes.

FAQ for Twelve Head Vial Cap Sealing Machine

What is a Twelve Head Vial Cap Sealing Machine?

The Twelve Head Vial Cap Sealing Machine (Model: ACS-400) is a high-speed, fully automatic rotary vial sealing machine designed to apply and crimp aluminum caps (plain, flip-off, and tear-off) onto pre-stopped glass vials. With twelve sealing heads, it delivers very high output and is ideal for large-scale sterile injectable production in pharmaceutical and biotech industries.

What is the production capacity of the Twelve Head Vial Cap Sealing Machine?

The machine has a high production capacity of 250 to 400 vials per minute, depending on vial size, cap type, and product characteristics. It is one of the fastest models in the range, making it suitable for high-volume pharmaceutical manufacturing lines.

What vial and cap sizes can the machine handle?

The Twelve Head Vial Cap Sealing Machine supports a wide range of formats:

Vial Diameter: 15 mm to 80 mm
Vial Height: 20 mm to 180 mm
Cap Sizes: 13 mm, 20 mm, and 28 mm (with suitable change parts)

It works efficiently with both molded and tubular glass vials using plain aluminum, flip-off, or tear-off caps.

What safety features does the Twelve Head Vial Cap Sealing Machine include?

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

No Vial – No Capping system
No Stopper on Vial – Machine Stop
No Cap/Seal in Chute – Machine Stop (via photo sensor)
Clutch mechanism to prevent vial breakage due to odd-shaped or oversized vials
Spring-loaded free-spinning sealing heads

These features minimize product loss and ensure smooth, damage-free operation.

What are the key benefits and optional features?

Key benefits include very high production speed, precise and wrinkle-free hermetic sealing, quick size changeover, low particle generation, low noise & energy consumption, and easy maintenance. Optional features include:

PLC with HMI and touchscreen
Laminar Air Flow (LAF) unit
Full aluminum profile safety cabinet
Flip-off sealing chuck
Camera inspection system
21 CFR Part 11 compliance

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