Vial Capping Machine

Q: What vial and cap sizes can the Vial Capping Machine handle?

The 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, 28 mm, 30 mm, and 33 mm (with suitable change parts) It works efficiently with both molded and tubular glass vials using plain aluminum, flip-off, or tear-off caps.

Description

Vial Capping Machine is an automated or semi-automated device designed primarily for the pharmaceutical, biotechnology, and laboratory industries to securely seal or crimp caps onto glass or plastic vials containing liquids, powders, or other substances. These machines ensure container closure integrity, maintaining sterility, product stability, and preventing contamination by applying precise force to aluminum, plastic, or flip-off caps over rubber stoppers.

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

Salient Features of Vial Capping Machine

A complete cGMP model.
“No Stopper on Vial Before Sealing – 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.

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

Working Principle of 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 Vial Capping 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

Advantages of Vial Capping Machine

High precision and repeatability to meet regulatory standards for seal integrity.

Adaptable to various vial sizes and cap types.

Efficiency: Reduces manual labor, minimizes errors, and supports cleanroom or isolator integration for sterile processing.

Customizable: Options for touch-screen controls, multi-language interfaces, and integration with upstream/downstream equipment.

Key Features of Vial Capping Machine

Types and Configurations:
- Benchtop/Semi-Automatic Models: Compact systems like the Vial Sealing System for manual or low-volume operations, where operators place vials and caps, and the machine handles sealing with controlled force for precise stopper compression.
- Automated/High-Speed Models: Rotary or linear systems with multiple heads capable of processing 400–13,000 vials per minute. These integrate with filling and labeling lines, using star wheels, vibratory feeders for caps, and spinning rollers or crimping discs to roll or crimp the cap skirt.
- Nested or Specialized Variants: Designed for pre-nested trays of vials, where the machine automatically places and crimps caps without removing vials from trays.

Core Process:
- Vials are fed via conveyor, turntable, or tray.
- Caps are supplied automatically from a vibratory bowl or electromagnetic feeder.
- The machine positions the cap on the vial, then applies torque or crimping via servo motors, plungers, and rollers to form a tamper-evident seal.
- Quality checks may include force monitoring, torque verification, or rejection of misaligned vials.

FAQ for Vial Capping Machine

What is a Vial Capping Machine?

The Vial Capping Machine is a fully automatic rotary machine designed to apply and seal aluminum caps (plain, flip-off, and tear-off types) on glass vials with high precision and consistency. It is widely used in the pharmaceutical and biotech industries for sealing injectable products such as vaccines, antibiotics, sterile powders, and liquid injectables. Available in four-head and eight-head models, it ensures hermetic, tamper-evident, and leak-proof sealing while complying with cGMP standards.

What is the production capacity of the Vial Capping Machine?

The Vial Capping Machine is available in different configurations:

Four Head Model: Up to 100–120 vials per minute
Eight Head Model: Up to 180–200 vials per minute

The actual output depends on vial size, cap type, and product characteristics. The Eight Head model is ideal for high-volume production.

What vial and cap sizes can the Vial Capping Machine handle?

The 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, 28 mm, 30 mm, and 33 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 Vial Capping Machine include?

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

No Vial – No Cap system
No Stopper on Vial – Machine Stop
No Cap in Chute – Machine Stop (via photo sensor)
Safety clutch mechanism to prevent vial breakage
Spring-loaded sealing heads for flexibility

These features minimize product loss and ensure smooth operation.

What are the key benefits and optional features of the Vial Capping Machine?

Key benefits include high-speed operation, precise hermetic sealing, quick size changeover, low particle generation, easy maintenance, and consistent sealing quality. Optional features include:

PLC with HMI and touchscreen interface
Laminar Air Flow (LAF) unit
Full safety cabinet enclosure
Camera inspection system
21 CFR Part 11 compliance
Variable speed cap feeder

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