Four Head Vial Filling Machine

Description

Four Head Vial Filling Machine is an Automated Pharmaceutical Packaging Equipment designed for the precise filling of injectable liquids into glass vials, followed by rubber stoppering. It is a compact, high-speed model commonly used in medium-batch production for sterile injectables in the pharmaceutical, biotech, and healthcare industries. This machine ensures compliance with cGMP standards, minimizes contamination risks, and optimizes efficiency by handling up to 120 vials per minute, depending on factors like liquid viscosity, vial size, and fill volume.

Vial Feeding: Sterilized and siliconized vials are fed via an in-feed turntable or unscrambler onto a conveyor belt or star wheel system.

Filling Process: Vials are positioned under four independent volumetric filling nozzles. The nozzles use a cam mechanism for up-and-down movement, descending to fill during star wheel rotation and ascending post-fill. Each head operates autonomously for continuous production.

Stoppering: Filled vials move to the rubber stoppering station, where a vibratory bowl feeder orients and supplies rubber bungs. A spring-loaded pressing roller or vacuum hold disc ensures precise placement.

Output: Vials are then transferred to an out-feed turntable for sealing, labeling, or further processing. The entire cycle is synchronized for seamless inline operation.

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

Salient Features of Four Head 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 Four Head 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 Four Head Vial Filling Machine

Model	ALVF-80
Filling Heads	Four
Production Rate	Up to 80 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	1.5 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2200mm (L) x 850mm (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 Four Head Vial Filling Machine

Enhanced Production Throughput

High Filling Accuracy

Versatility and Quick Changeovers

CGMP Compliance and Hygiene

Key Components of Four Head Vial Filling Machine

Compact Design: Fully constructed with stainless steel (SS 304/316) for durability and easy cleaning, including the frame, contact parts, and enclosures. It features an acrylic cabinet for visibility and protection.

Safety Mechanisms: Equipped with a “No Vial, No Fill” system to prevent liquid wastage and a special clutch for detecting overturned or oversized vials, halting operations to avoid damage.

Drive System: Powered by high-quality imported gear motors for vibration-free performance and no oil leakage.

Customization Options: Available with stainless steel piston pumps for standard filling; peristaltic pumps can be added for higher precision. Nitrogen flushing before/after filling is optional for oxygen-sensitive products.

Sterile Operation: Designed for use under laminar flow hoods, with minimal distance between filling and stoppering units to reduce contamination.

FAQ for Four Head Vial Filling Machine

What is a Four Head Vial Filling Machine and what is it used for?

A Four Head Vial Filling Machine is an automatic volumetric liquid filling equipment designed to fill injectable liquids into glass vials with high precision. It is widely used in the pharmaceutical industry for aseptic filling of vaccines, antibiotics, and other sterile liquid formulations. The four-head configuration allows for higher production rates compared to single or two-head models while maintaining accuracy and compliance with GMP standards.

What is the production output capacity of the Four Head Vial Filling Machine?

The machine typically delivers an output of 3,600 to 7,200 vials per hour, depending on the vial size, fill volume (usually 2 ml to 250 ml), and viscosity of the liquid. This makes it suitable for medium to small batch production in pharmaceutical manufacturing units.

What vial sizes and fill volumes can the Four Head Vial Filling Machine handle?

It is designed to handle standard pharmaceutical vials ranging from 2 ml to 250 ml (with appropriate change parts). The machine supports single-dose or multi-dose filling with high accuracy, usually within ±1% variation, ensuring consistent dosing for injectable products.

What are the key features of this Four Head Vial Filling Machine?

Key features include:
– Stainless steel construction for easy cleaning and corrosion resistance
– Volumetric piston-based filling system
– No vial – no fill mechanism to prevent wastage
– Integrated diving nozzles for bottom-up filling to minimize foaming and spillage
– Variable speed drive for adjustable output
– Compatibility with rubber stoppering and sealing units
– Compact design with low power consumption (typically 2 HP)

Is the Four Head Vial Filling Machine suitable for sterile and GMP-compliant production?

Yes, the machine is built to meet stringent GMP (Good Manufacturing Practice) requirements for sterile injectable production. It features contact parts made of SS 316L, easy-to-clean design, and optional accessories like laminar airflow, in-feed turntables, and nitrogen flushing to maintain product integrity and prevent contamination.

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