The Eight Head Vial Filling Machine (also known as an Automatic Eight Head Vial Filling and Rubber Stoppering Machine) is a specialized piece of pharmaceutical equipment designed for the automated filling and rubber stoppering of injectable liquids into glass vials. It is commonly used in sterile manufacturing environments for pharmaceuticals, such as injectables ranging from 1-30 ml in volume. This compact, high-precision machine ensures aseptic conditions, minimizes human intervention, and complies with cGMP (Current Good Manufacturing Practice) standards. It is suitable for medium to large batch productions in industries like pharmaceuticals, cosmetics, and food ancillaries.
Eight Head Vial Filling Machine Video
Key Features
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Construction and Materials: Built with stainless steel (SS 316L) components for durability and corrosion resistance. The filling unit includes eight independent filling heads, syringes, and nozzles made from high-quality SS 316 construction. Both glass and SS syringes are compatible for versatile liquid handling.
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Automation and Controls: Equipped with PLC (Programmable Logic Controller) and HMI (Human-Machine Interface) for user-friendly operation. Includes a “No Vial, No Fill” sensor system to prevent liquid wastage, and variable speed controls via AC drives.
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Safety and Hygiene: Operates under laminar airflow protection to maintain sterility. All assemblies under the top plate are easily accessible for cleaning and maintenance. Pneumatic modules ensure smooth rubber stoppering without contamination.
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Additional Components: Features an infeed turntable, Delrin slat conveyor belt for vial transport, star wheel for precise vial holding during filling, and a vibratory bowl with chute for rubber bung orientation. Nitrogen purging nozzles are integrated for gas flushing to reduce oxygen exposure in sensitive liquids.
Working Principle
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Vial Feeding: Sterilized and siliconized vials are fed via an unscrambler onto a conveyor belt and positioned accurately under the filling station using a star wheel.
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Filling Operation: Each of the eight heads independently dispenses liquid via piston or peristaltic pumps, with adjustable stroke lengths for volumes from 2 ml to 250 ml. Nitrogen purging occurs before filling to maintain product integrity.
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Stoppering: Immediately after filling, rubber stoppers (up to 20 mm diameter, with ±1% accuracy) are automatically pressed into place using a vacuum bung hold disc and pneumatic system. The minimal distance between filling and stoppering units reduces contamination risks.
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Output and Discharge: Filled and stoppered vials are transferred to an outfeed turntable for further processing (e.g., capping or labeling). The machine drives through a high-quality imported gear motor for vibration-free performance.
Applications
Primarily used for filling sterile injectables like vaccines, antibiotics, and biologics in pharmaceutical production lines. It integrates seamlessly into full aseptic lines, including vial washing, drying tunnels, capping, and labeling stations.
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 Automatic Vial Filler
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 Eight Head Vial Filling Machine
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Model |
ALVF-120 |
| Filling Heads |
Eight |
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Production Rate |
Up to 150 Vials/Minute |
| Vial Diameter |
15mm to 70mm |
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Vial Height |
25mm to 140mm |
| Filling Precision |
±1% |
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Power Required |
2 H.P. |
| Electrical Characteristics |
440 Volts, 3 Phase, 50 Hertz |
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Overall Dimension |
3000mm (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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