Eight Needle Vial Filling Machine

Description

Eight Needle Vial Filling Machine is an advanced pharmaceutical packaging equipment designed for the high-speed, precise filling of liquid injectables (such as pharmaceuticals, vaccines, or biologics) into glass vials. It features eight filling needles (or heads) to enable simultaneous filling of multiple vials, making it suitable for medium to large batch production in aseptic environments. This machine typically integrates filling, nitrogen purging (to displace oxygen and prevent oxidation), and rubber stoppering operations in a single automated line, adhering to cGMP (Current Good Manufacturing Practice) standards for sterility and accuracy.

Vial Feeding: Empty sterilized vials are loaded via a hopper or unscrambler and transferred onto a conveyor belt or rotary table.

Positioning: Vials are indexed precisely under the eight filling needles using a star wheel or timing screw mechanism.

Purging and Filling: Nitrogen is purged through the needles to evacuate air, followed by controlled liquid injection. The needle height adjusts automatically to avoid foaming or splashing.

Stoppering: Filled vials move to the stoppering station, where rubber stoppers are oriented, picked, and pressed into place using vacuum-assisted or vibratory systems.

Output: Completed vials exit for capping, labeling, or inspection, with reject mechanisms for under/over-filled units.

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

Salient Features of Eight Needle Vial Filling Machine

Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
No cross contamination.
All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.
Variable A.C. frequency drive for speed adjustment.
Suitable for the filling Volume of 2ml to 250ml.

Digital Vial Counter for counting production output.
“No Vial – Machine Stop” System.
On-line Mechanism., “No Vial – No Filling” System.
Easy to validate filling system for small/large batch production.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Eight Needle 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 Eight Needle Vial Filling Machine

Model	ALVF-120
Filling Heads	Eight
Production Rate	Up to 150 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	2 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
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.

Types of Vial Filling Machine

Automatic Vial Filling Machine

High Speed Vial Filling Machine

Vial Liquid Filling Machine

Vial Powder Filling Machine

Automatic Vial Filling and Rubber Stoppering Machine

Lab Scale Vial Filling Stoppering & Cap Sealing Machine

Injectable Vial Powder Filling & Stoppering Machine

Peristaltic Pump based Vial Filling Machine

Applications of Vial Filling Machine

Advantages of Eight Needle Vial Filling Machine

High throughput reduces labor costs and minimizes human error.

Ensures sterility with laminar airflow compatibility and HEPA-filtered environments.

Scalable for R&D to commercial production, with quick changeover for different vial formats.

Low maintenance due to robust design and independent head operation.

Key Components of Eight Needle Vial Filling Machine

Filling Capacity: Up to 12,000 vials per hour, depending on vial size (e.g., 2ml to 50ml) and product viscosity.

Filling Heads: Eight precision nozzles for liquid dispensing, often equipped with stainless steel piston pumps or optional peristaltic pumps for minimal shear and high accuracy (±0.5% fill volume tolerance).

Nitrogen Purging: Pre-filling gas flushing to maintain product stability.

Stoppering Mechanism: In-line rubber bung insertion using a vibrating chute and SS 316L rollers for secure sealing, with options for partial or full stoppering.

Construction: Made from stainless steel (SS 304/316) for corrosion resistance, with easy-to-clean surfaces and minimal dead zones to prevent contamination.

Controls: PLC (Programmable Logic Controller) with HMI (Human-Machine Interface) for recipe-driven operation, fault detection, and real-time monitoring.

FAQ for Eight Needle Vial Filling Machine

What is the production speed of the Eight Needle Vial Filling Machine?

The machine is designed for high-speed production, capable of filling and stoppering 80 to 120 vials per minute. The exact speed depends on the vial diameter, the fill volume of the liquid, and the characteristics of the product being filled.

How does the “No Vial – No Filling” system work?

This is a critical safety and efficiency feature. The machine uses a set of sensors to detect the presence of vials on the conveyor. If a vial is missing in the sequence, the machine automatically skips that cycle for that specific needle. This prevents liquid spillage, reduces product wastage, and keeps the machine base clean.

What filling range and accuracy does the machine offer?

The machine is highly versatile and can handle fill volumes from 2ml to 100ml (and up to 250ml with specific syringe changes). By utilizing high-quality SS 316L volumetric syringes, it achieves a filling accuracy of +/- 1% on a single dose, ensuring consistent dosage across all vials.

Can the machine handle different vial and stopper sizes?

Yes. The machine is designed for flexibility. It can process various vial sizes with the help of “change parts” (like star wheels and guides). It is also equipped to handle both 13mm and 20mm rubber stoppers (plain or slotted), which are applied immediately after filling to ensure the product remains sterile.

Does the machine comply with pharmaceutical industry standards?

Absolutely. The Eight Needle Vial Filling Machine is built to meet cGMP (current Good Manufacturing Practices) standards. All contact parts are made of AISI SS 316L to prevent contamination, while non-contact parts are made of AISI SS 304. The design also allows for easy cleaning and sterilization (CIP/SIP) to maintain a sterile environment.

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