Vial Powder Filling Line

The line typically handles glass vials ranging from 2 ml to 100 ml. Production speeds range from 20 to 300+ vials per minute, depending on whether the configuration is semi-automatic or a high-speed fully automatic model.

Automatic lines integrate machines for washing, sterilizing, filling, sealing, inspecting, and labeling into a cohesive, high-speed system with minimal human intervention (also known as High-Speed or Production Scale Vial Filling Lines). Semi-automatic lines use independent machines that communicate with each other and are suited for lower-cost or small-scale production.

Core machines include the Vial Washing Machine, Sterilization Tunnel, Vial Powder Filling Machine, Vial Cap Sealing Machine, Vial Inspection Machine, and Vial Sticker Labeling Machine. All operate as a unified system.

It uses a gripper system that holds vials by the neck, flips them, and advances them on a rotating system. It cleans interior and exterior surfaces with high-pressure purified water sprays, removes dust and particulates, drains residual water, and prepares vials for sterilization—without non-contact machine parts touching the vials. It handles 2–100 ml vials.

It sterilizes and depyrogenates cleaned empty glass vials using forced convection of filtered air through HEPA filters (or controlled dry heat in semi-automatic setups). It eliminates microbial contamination, ensures uniform high-temperature distribution, cools vials safely, and supports aseptic powder filling under continuous operation.

It is a monoblock device that dispenses precise powder doses into vials and performs stoppering/bunging on the same platform under controlled aseptic conditions. It controls fill weight accurately, minimizes wastage, and adjusts easily for different vial sizes. All contact parts are stainless steel 316L or FDA-certified materials for cGMP compliance.

It places rubber stoppers on filled vials, applies and crimps aluminium seals (or PP/Flip-off caps) with firm pressure to create an airtight sterile closure, detects missing stoppers or seals, and maintains seal integrity. It features a vibratory bowl feeder for continuous online operation and can be adjusted for various vial and cap sizes.

The Inspection Machine detects foreign particles, checks fill level and powder appearance, identifies glass cracks or defects, and automatically rejects non-conforming vials using cameras, sensors, and rejection units. The Labeling Machine accurately applies labels, prints batch codes and expiry dates, verifies label presence, ensures alignment, and handles various vial diameters at speeds up to around 100 vials per minute.

It is widely used in the Pharmaceutical, Nutraceutical, Herbal, Ayurvedic, Biotech, Cosmetic, and Chemical industries. The systems are designed for cGMP, FDA, and ISO compliance, with contact parts in stainless steel 316L or FDA-approved materials to support sterile injectable powder production.