An Automatic Vial Filler is a specialized machine used primarily in the pharmaceutical, biotechnology, and cosmetics industries to fill vials (small glass or plastic containers) with liquid or semi-liquid products in a precise, sterile, and high-speed manner. Vial Filler machines are critical for ensuring accuracy, consistency, and compliance with regulatory standards like cGMP (current Good Manufacturing Practices).
Automatic Vial Filler Video
Key Features of an Automatic Vial Filler
- Filling Mechanisms:
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Peristaltic pumps – Ideal for sterile, low-viscosity liquids; easy to clean.
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Piston pumps – Suitable for viscous liquids or suspensions.
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Time-pressure filling – Used for high-precision, foam-sensitive products.
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Mass flow filling – For high-accuracy filling based on weight.
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- Vial Handling:
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Automatic infeed systems (e.g., rotary tables, conveyor belts).
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Denesting and positioning of vials.
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Supports various vial sizes (2mL to 100mL typically).
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- Sterility & Cleanliness:
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Laminar airflow hoods (LAF) or isolators.
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Clean-in-place (CIP) and sterilize-in-place (SIP) capabilities.
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HEPA filtration.
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- Capping & Sealing:
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Integrated crimping or screw-capping stations.
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Stopper placement (rubber stoppers for injectables).
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- Controls & Monitoring:
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PLC (Programmable Logic Controller) with HMI touchscreen.
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Fill volume verification via check-weigh systems or vision inspection.
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Rejection of under/over-filled or defective vials.
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Common Applications
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Injectable drugs (vaccines, insulin, biologics)
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Ophthalmic solutions
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Diagnostic reagents
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Cosmetics (serums, essences)
Advantages
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High accuracy (±0.5% fill volume)
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Reduced contamination risk
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Scalable for small batch to high-volume production
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Full traceability and data logging
Salient Features of Vial Filler
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Suitable for the filling Volume of 2ml to 250ml.
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Piston pump/Peristaltic pump aseptic filling.
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Filling accuracy of ±0.5% to ±1%.
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No cross contamination.
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Easy to validate filling system for small/large batch production.
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All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.
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Variable A.C. frequency drive for speed adjustment.
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Digital Vial Counter for counting production output.
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In-feed Turn Table/ Unscrambler for automatic feeding of objects.
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On-line Mechanism.
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“No Vial – No Filling” System.
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“No Vial – Machine Stop” System.
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IQ/OQ documentation can be provided.
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PLC system with Graphical User Interface. (Optional)
Process Operation of Vial Filling Machine
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 Automatic Vial Filling Machine
| Model | ALVF-40 | ALVF-80 | ALVF-120 | ALVF – 250 |
| Filling Heads | Two | Four | Eight | Twelve |
| Production Rate | Up to 40 Vials/Minute | Up to 80 Vials/Minute | Up to 150 Vials/Minute | Up to 250 Vials/Minute |
| Input Specification | ||||
| Vial Diameter | 15mm to 70mm | 15mm to 70mm | 15mm to 70mm | 15mm to 70mm |
| Vial Height | 25mm to 140mm | 25mm to 140mm | 25mm to 140mm | 25mm to 140mm |
| Filling Precision | ±1% | ±1% | ±1% | ±1% |
| Power Required | 1 H.P. | 1.5 H.P. | 2 H.P. | 2 H.P. |
| Electrical Characteristics | 440 Volts, 3 Phase, 50 Hertz | 440 Volts, 3 Phase, 50 Hertz | 440 Volts, 3 Phase, 50 Hertz | 440 Volts, 3 Phase, 50 Hertz |
| Overall Dimension | 2050mm (L) x 850mm (W) x 1700mm (H) | 2200mm (L) x 850mm (W) x 1700mm (H) | 3000mm (L) x 945mm (W) x 1700mm (H) | 3500mm (L) x 945mm (W) x 1700mm (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.
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