An Eight Syringe Vial Filler is a semi-automatic or automatic pharmaceutical filling machine designed for precise, high-volume dispensing of liquid formulations into sterile vials. It utilizes eight stainless steel (SS 316L) syringes equipped with non-return valves to ensure consistent volume delivery and prevent backflow or variation during the filling process. This configuration allows for simultaneous filling of up to eight vials per cycle, achieving output speeds of 2,400–4,000 vials per hour, depending on vial size, liquid viscosity, and operational settings. These machines are commonly used in GMP-compliant environments for injectable drugs, vaccines, or biotech products, emphasizing sterility, accuracy (±0.5–1% fill tolerance), and minimal particle generation.
Eight Syringe Vial Filler Video
Key Features and Components
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Filling Mechanism: Eccentric cam-driven syringes mounted on a rotary or linear station. Liquid is drawn from a reservoir through transparent silicone tubing and dispensed via diving nozzles that lower into the vial neck during filling and retract afterward to avoid drips. Pre- and post-nitrogen flushing options are available for oxygen-sensitive products.
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Vial Handling: Incoming sterilized, siliconized vials are fed via a slat conveyor or turntable unscrambler. A star wheel grips vials precisely under the nozzles; a “no vial, no fill” sensor prevents errors.
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Stoppering and Sealing: Integrated rubber stoppering station delivers two vials at a time to a vacuum or mechanical plugger, followed by optional aluminum cap crimping for secure closure.
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Construction: Full SS 316 construction with polished interiors for easy cleaning and validation. Includes a compact control panel for stroke length adjustment to vary fill volumes.
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Safety and Compliance: cGMP, FDA, and CE certified; features like laminar airflow compatibility, HEPA filtration integration, and isolator/RABS enclosure options for aseptic processing.
Typical Operation Cycle
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Vials enter via conveyor and are positioned under the 8-nozzle filling head.
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Nozzles descend, fill under controlled pressure, then ascend.
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Star wheel advances vials to stoppering station for plug insertion.
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Vials exit to capping/labeling line.
Salient Features of Vial Filling Machine
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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 Syringe Vial Filler
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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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