The 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.
Four Needle Vial Filling Machine Video
Key Features
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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.
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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.
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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.
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Drive System: Powered by a high-quality imported gear motor for smooth, vibration-free operation without oil leakage.
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Optional Enhancements: Nitrogen purging nozzles for gas flushing, peristaltic or piston pumps for precise volume control, and in-line check-weighing for quality assurance.
How It Works
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Vial Feeding: Empty, pre-washed vials are fed onto a conveyor or rotary infeed system.
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Positioning: Vials are gripped by a star wheel and rotated into position under the four filling needles.
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Filling: Needles descend via cam mechanism, purge nitrogen (if equipped), and inject the liquid. The star wheel rotates, lifting the needles post-fill.
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Transfer: Four filled vials are delivered simultaneously to the conveyor for stoppering.
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Stoppering: Vials enter the stoppering station, where they collect rubber bungs from a vibratory chute. A fixed pressing roller secures the stoppers.
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Output: Stoppered vials exit via an outfeed star wheel for capping, labeling, or further packaging.
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 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.
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