Four Needle Vial Filling Machine

Q: What are the key hygiene and maintenance features?

The machine is built to comply with cGMP standards . All 'contact parts' (parts that touch the product) are made from AISI SS 316L , while the main framework is constructed from SS 304 . The compact design minimizes the distance between filling and stoppering to reduce contamination risks, and the surfaces are finished in a smooth matt style for easy cleaning and sterilization.

Description

Four Needle Vial Filling 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 pharmaceutical, biotech, and healthcare manufacturing to ensure precise, sterile, and efficient production of vials containing medications, vaccines, or other liquid formulations. This compact, inline machine typically handles vials ranging from 2ml to 50ml in capacity and operates at speeds of up to 80-120 vials per minute, making it ideal for small to medium batch production.

Vial Feeding: Empty, pre-washed vials are fed onto a conveyor or rotary infeed system.

Positioning: Vials are gripped by a star wheel and rotated into position under the four filling needles.

Filling: Needles descend via cam mechanism, purge nitrogen (if equipped), and inject the liquid. The star wheel rotates, lifting the needles post-fill.

Transfer: Four filled vials are delivered simultaneously to the conveyor for stoppering.

Stoppering: Vials enter the stoppering station, where they collect rubber bungs from a vibratory chute. A fixed pressing roller secures the stoppers.

Output: Stoppered vials exit via an outfeed star wheel for capping, labeling, or further packaging.

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

Salient Features of Four Needle Vial Filling Machine

Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
In-feed Turn Table/ Unscrambler for automatic feeding of objects, “No Vial – Machine Stop” System.
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 cross contamination.
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 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 Four Needle 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 Needle Vial Filling Machine

Higher Production Output

Improved Efficiency & Time Saving

Better Sterility & Low Contamination Risk

Consistency and Batch Uniformity

Lower Labor Requirement

Key Components of Four Needle Vial Filling Machine

Filling Mechanism: Equipped with four precision filling needles (nozzles) that deliver liquid via a cam-driven up-and-down motion. The needles lower into the vial held by a rotary star wheel for accurate dosing, then retract during filling to minimize splashing or foaming. It supports “no vial, no fill” sensors to prevent product wastage.

Stoppering Unit: Integrated rubber stoppering system where filled vials are transferred to a conveyor, pick up stoppers from a chute, and are pressed into place by spring-loaded rollers. This ensures a secure seal while maintaining sterility.

Construction and Compliance: Made from stainless steel (SS 304/316) with polished contact parts for easy cleaning and minimal contamination risk. It adheres to cGMP standards and can be integrated into cleanroom environments with laminar airflow.

Drive System: Powered by a high-quality imported gear motor for smooth, vibration-free operation without oil leakage.

Optional Enhancements: Nitrogen purging nozzles for gas flushing, peristaltic or piston pumps for precise volume control, and in-line check-weighing for quality assurance.

FAQ for Four Needle Vial Filling Machine

What is the production capacity of the Four Needle Vial Filling Machine?

The Four Needle (or Four Syringe) model is designed for medium batch production. It can achieve a production rate of up to 80 to 120 vials per minute (approximately 7,200 vials per hour), depending on the vial size and liquid characteristics.

What range of vial sizes and fill volumes can this machine handle?

This machine is highly versatile, accommodating glass or plastic vials with diameters ranging from 15mm to 70mm and heights from 25mm to 140mm. It supports a wide filling range, typically from 2ml to 100ml (up to 250ml on specific models), using high-precision Stainless Steel 316L syringes.

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

To prevent product wastage and maintain a clean working environment, the machine is equipped with a specialized sensor. If a vial is missing from its designated slot in the star wheel during the filling cycle, the sensor signals the machine to skip that specific filling stroke, ensuring no liquid is discharged unless a container is present.

Can this machine be integrated into a complete production line?

Yes. While it functions as a standalone unit, it is designed for seamless “on-line” integration. It features an in-feed turn table (unscrambler) for automatic feeding and can be connected to downstream equipment like rubber stoppering units, cap sealing machines, and labeling machines to form a full sterile filling line.

What are the key hygiene and maintenance features?

The machine is built to comply with cGMP standards. All “contact parts” (parts that touch the product) are made from AISI SS 316L, while the main framework is constructed from SS 304. The compact design minimizes the distance between filling and stoppering to reduce contamination risks, and the surfaces are finished in a smooth matt style for easy cleaning and sterilization.

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