Four Syringe Vial Filling Machine

Q: What is the difference between a "Four Needle" and a "Four Syringe" Vial Filling Machine?

In the context of this machinery, both terms refer to the same mechanism. The 'Four Syringe' designation highlights the four volumetric piston pumps (syringes) that precisely measure and discharge the liquid into the vials. This configuration allows for higher throughput compared to single or double-head models.

Q: What is the filling accuracy and range of this machine?

The machine is engineered for high precision, offering a filling accuracy of ±1% . It is versatile enough to handle filling volumes ranging from 2ml to 100ml (and up to 250ml with specific syringe changes), making it suitable for a variety of injectable products and clinical trial batches.

Q: Does the machine support aseptic or sterile processing?

Yes. The Four Syringe Vial Filler is designed for cleanroom environments. It features a bottom-up filling system where the nozzles descend into the vial and rise during the fill to minimize foaming and splashing. Furthermore, all contact parts are crafted from AISI SS 316L , and the machine can be equipped with laminar air flow (LAF) hoods to maintain sterility.

Q: How are the vials transported through the filling and stoppering stations?

The machine utilizes a synchronized star wheel mechanism . Vials are picked up from the conveyor and held firmly by the star wheel as they move through the filling station. This ensures each vial is perfectly centered under the syringes. After filling, the star wheel continues to transport the vials to the rubber stoppering station for immediate sealing.

Q: What happens if a vial is missing during the filling cycle?

The machine includes a 'No Vial – No Filling' safety sensor . If the sensor detects a gap in the production line where a vial should be, it automatically prevents the corresponding syringe from discharging. This prevents liquid waste, protects the conveyor system from spills, and ensures the machine remains clean during operation.

Description

Four Syringe Vial Filling Machine is a semi-automatic, high-precision filling system designed for pharmaceutical, biotechnology, and laboratory applications. It enables simultaneous filling of four pre-filled syringes or vials in a single cycle, ensuring accuracy, sterility, and compliance with GMP (Good Manufacturing Practices) standards. Ideal for small to medium-scale production, R&D, and clinical trials, this machine minimizes manual intervention while maximizing efficiency and product safety. A Four Syringe Vial Filling Machine consists of a filling unit with four syringes (SS 316 or glass) connected to nozzles that dispense a fixed volume of liquid into vials. The machine is typically integrated with a conveyor system, sensors, and control panel for smooth and continuous operation.

Main Components:

Four Syringes & Nozzles: Precisely measure and dispense liquid into vials
Conveyor Belt System: Moves vials through filling stations
Turntable/Unscrambler: Feeds empty vials into the machine
Sensors & Control System: Ensure accurate positioning and “no vial–no filling” operation
Storage Tank & Tubing: Supplies liquid to syringes
Stoppering Unit (optional): Inserts rubber stoppers 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 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 Syringe 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 Syringe 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 Syringe Vial Filling Machine

High Throughput with minimal footprint

Low Product Loss due to precision filling

Easy Changeover (<15 mins for format change)

User-Friendly – minimal training required

Cost-Effective for small-batch production

Key Components of Four Syringe Vial Filling Machine

Four-Head Filling: Equipped with four independent peristaltic or piston pumps for simultaneous filling of 4 syringes/vials per cycle.

Filling Range: 0.1 mL to 100 mL (customizable based on syringe size).

Accuracy: ±0.5% filling accuracy with digital calibration.

Sterile Operation: Fully compatible with aseptic processing; uses disposable fluid paths and autoclavable components.

Touchscreen HMI: 7-inch color touchscreen with recipe storage, batch logging, and real-time monitoring.

Nozzle Design: Anti-drip, self-cleaning nozzles with individual flow control.

Material: Stainless Steel 316L contact parts; GMP-compliant.

FAQ for Four Syringe Vial Filling Machine

What is the difference between a “Four Needle” and a “Four Syringe” Vial Filling Machine?

In the context of this machinery, both terms refer to the same mechanism. The “Four Syringe” designation highlights the four volumetric piston pumps (syringes) that precisely measure and discharge the liquid into the vials. This configuration allows for higher throughput compared to single or double-head models.

What is the filling accuracy and range of this machine?

The machine is engineered for high precision, offering a filling accuracy of ±1%. It is versatile enough to handle filling volumes ranging from 2ml to 100ml (and up to 250ml with specific syringe changes), making it suitable for a variety of injectable products and clinical trial batches.

Does the machine support aseptic or sterile processing?

Yes. The Four Syringe Vial Filler is designed for cleanroom environments. It features a bottom-up filling system where the nozzles descend into the vial and rise during the fill to minimize foaming and splashing. Furthermore, all contact parts are crafted from AISI SS 316L, and the machine can be equipped with laminar air flow (LAF) hoods to maintain sterility.

How are the vials transported through the filling and stoppering stations?

The machine utilizes a synchronized star wheel mechanism. Vials are picked up from the conveyor and held firmly by the star wheel as they move through the filling station. This ensures each vial is perfectly centered under the syringes. After filling, the star wheel continues to transport the vials to the rubber stoppering station for immediate sealing.

What happens if a vial is missing during the filling cycle?

The machine includes a “No Vial – No Filling” safety sensor. If the sensor detects a gap in the production line where a vial should be, it automatically prevents the corresponding syringe from discharging. This prevents liquid waste, protects the conveyor system from spills, and ensures the machine remains clean during operation.

Countries We Export to

Partner with Industry Experts

Connect with our engineering team to discuss your specific production requirements. We provide customized, cGMP-compliant machinery solutions designed to optimize your manufacturing facility and maximize output.

GET A QUOTE!