Four Syringe Vial Filler

Q: What safety features are included to prevent liquid wastage?

The machine is equipped with an advanced 'No Vial – No Filling' sensor system . If a vial is missing from the conveyor or the star wheel during the cycle, the machine will automatically detect the gap and bypass the filling stroke for that specific head. This prevents product loss and keeps the conveyor system clean.

Q: Is the Four Syringe Vial Filler compliant with sterile manufacturing standards?

Absolutely. The machine is built according to cGMP (current Good Manufacturing Practice) standards. All parts that come into contact with the liquid are made from AISI Stainless Steel 316L , and the exterior is finished in SS 304. The design also facilitates 'bottom-up' filling to reduce foaming and air entrapment, making it ideal for aseptic processing environments.

Description

Four Syringe Vial Filler is a compact, Automatic benchtop filling machine designed for precise aseptic filling and stoppering of pharmaceutical vials using a four-syringe peristaltic or rotary piston dosing system. Ideal for small-batch production, R&D, clinical trials, and GMP-compliant operations, this equipment ensures high accuracy (typically ±1-2% fill volume) while minimizing contamination risks through integrated isolator technology or laminar flow hood compatibility. A Four Syringe Vial Filler consists of a filling system with four calibrated syringes, each connected to a filling nozzle. These syringes operate together to fill four vials simultaneously with a pre-set quantity of liquid. The machine is usually integrated with a conveyor system and control panel for continuous and automated operation.

Main Components:

Four Syringes (SS 316 or glass): Measure and deliver accurate volumes of liquid
Filling Nozzles: Dispense liquid into vials without spillage
Conveyor Belt: Moves vials through the filling station
Vial Feeding System (Turntable): Supplies empty vials to the machine
Liquid Storage Tank: Holds the product to be filled
Sensors & Control Unit: Ensure proper positioning and “no vial–no filling” function
Optional Stoppering Unit: Seals vials after filling

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

Salient Features of Four Syringe Vial Filler

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 Syringe 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 Syringe Vial Filler

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 Syringe Vial Filler

High Filling Accuracy

Simultaneous Multi-Vial Filling

Ideal for Small & Precise Volumes

Reduced Contamination Risk

Cost-Effective for Medium Production

Key Components of Four Syringe Vial Filler

Filling Mechanism: Equipped with four independent syringe pumps for simultaneous filling of up to four vials per cycle, supporting volumes from 0.5 mL to 50 mL. Compatible with sterile ready-to-use (RTU) vials in nests or tubs.

Stoppering System: Automatic vacuum or mechanical placement of rubber stoppers and aluminum crimp seals, with optional capping for enhanced security.

Construction and Compliance: Stainless steel 316L build with USP Class VI materials; meets cGMP, FDA, and EU Annex 1 standards. Includes HEPA-filtered air flow and optional RTP (Rapid Transfer Port) for isolator integration.

Operation: User-friendly touchscreen HMI for recipe storage, changeover in under 15 minutes, and throughput of 400-1,200 vials/hour depending on configuration.

Versatility: Easily adaptable for nested vials, syringes, or cartridges; supports a range of viscosities (up to 20,000 cP) for liquids, suspensions, or biologics.

FAQ for Four Syringe Vial Filler

What is the maximum production speed of the Four Syringe Vial Filler?

The Four Syringe Vial Filler is designed for high-efficiency output, capable of reaching speeds of 80 to 120 vials per minute. The exact speed depends on the vial diameter, the viscosity of the liquid being filled, and the fill volume required for your specific application.

How accurate is the filling volume with the four-syringe system?

This machine utilizes high-precision volumetric piston pumps (syringes) that provide exceptional accuracy. You can expect a filling precision of ±1%, ensuring consistent dosing across all vials, which is a critical requirement for pharmaceutical and injectable manufacturing.

Can this machine handle different vial sizes and fill volumes?

Yes, the machine is highly versatile. It can typically accommodate vial sizes ranging from 2ml to 100ml with the appropriate syringe sets. While it is designed for standard glass vials, it can be adjusted for various diameters and heights using minimal “change parts,” allowing for quick transitions between different product batches.

What safety features are included to prevent liquid wastage?

The machine is equipped with an advanced “No Vial – No Filling” sensor system. If a vial is missing from the conveyor or the star wheel during the cycle, the machine will automatically detect the gap and bypass the filling stroke for that specific head. This prevents product loss and keeps the conveyor system clean.

Is the Four Syringe Vial Filler compliant with sterile manufacturing standards?

Absolutely. The machine is built according to cGMP (current Good Manufacturing Practice) standards. All parts that come into contact with the liquid are made from AISI Stainless Steel 316L, and the exterior is finished in SS 304. The design also facilitates “bottom-up” filling to reduce foaming and air entrapment, making it ideal for aseptic processing environments.

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