Aseptic Vial Filler Capper

The Aseptic Vial Filler Capper is a fully automated, high-precision machine designed for sterile filling and capping of liquid or lyophilized pharmaceutical products into glass or plastic vials under ISO 5 (Class 100) cleanroom conditions. It ensures zero microbial contamination through advanced isolation technology, in-line sterilization, and closed-system processing—critical for injectables, biologics, and high-potency drugs.

Vial Filler and Capper Machine Video

Salient Features of  Vial Filler and Capper

• Suitable for the filling Volume of 2ml to 250ml.

• Piston pump/Peristaltic pump aseptic filling.

• Filling accuracy of ±0.5% to ±1%.

• No cross contamination.

• Easy to validate filling system for small/large batch production.

• All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.

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

• Digital Vial Counter for counting production output.

• In-feed Turn Table/ Unscrambler for automatic feeding of objects.

• On-line Mechanism.

• “No Vial – No Filling” System.

• “No Vial – Machine Stop” System.

• IQ/OQ documentation can be provided.

• PLC system with Graphical User Interface. (Optional)

Process Operation of Vial Filling and Capping

The incoming dry vials (sterilized and siliconized) are fed through the unscrambler and suitably guided on the moving Delrin slat conveyor belt at the required speed of the correct placement below filling unit.

The filling unit consists of Filling Head, Syringes & Nozzles; Syringes & Nozzles are made of AISI SS 316L materials. A Star Wheel is provided which holds the vial during filling operation. A sensor is provided for ”No Vial-No Filling” operation. Syringes are mounted on eccentric block and driving through bottom main gear box. Volume can be increase & decrease by increasing or decreasing stroke length of piston as per filling size. Syringes is having non return valve for sucking and delivering situation to avoid volume variation. Liquid reaches to filling nozzles through silicon transparent pipe. Nozzles having up & down movement with help of cam mechanism, and it come down when vial hold by starwheel for filling operation and starts filling when it starts to move up and after completion of filling operation, starwheel delivers two vials together on conveyor for rubber stoppering operation.

Stoppering unit consist of Star wheel, Vibrator unit and Bowl. The sterilized and siliconized rubber stoppers stored in the vibrator bowl moves vertically to the rubber stopper chute. The vial is hold firmly by starwheel, which will be in continuous rotary motion and vial which is coming from filling unit get in to starwheel and move in rotary direction along with starwheel, during movement it picks up the rubber stopper from the exit end of the chute and rubber stopper pressed by fix single pressing roller, which is spring loaded. Then vial further move on conveyor and collected on out feed starwheel for next sealing operation.

Technical Specification of  Vial Filler and Capper

* 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.