Multi Syringe Vial Filler

Q: What is a Multi Syringe Vial Filler?

A Multi Syringe Vial Filler is a high-precision automatic liquid filling machine designed for aseptic filling of sterile injectable liquids into glass or plastic vials. It uses a multi-head piston-type syringe dosing system (2, 4, 8, or 12 heads) mounted on an eccentric block for simultaneous and accurate filling. The machine is ideal for pharmaceuticals, biotech, veterinary, and cosmetic industries to fill vaccines, antibiotics, biologics, serums, and other sterile liquid formulations. It supports fill volumes from 2ml to 250ml with excellent accuracy while operating under Class 100 / ISO 5 laminar airflow and complying with cGMP and FDA standards.

Q: What are the available models and production capacities?

We offer the following models in the ALVF series: ALVF-40 (2 Head) — Up to 40–60 vials per minute ALVF-80 (4 Head) — Up to 80–100 vials per minute ALVF-120 (8 Head) — Up to 120–150 vials per minute ALVF-250 (12 Head) — Up to 200–250 vials per minute Actual output depends on vial size, fill volume, and liquid viscosity. The machine handles vial diameters from 15mm to 70mm and heights from 25mm to 140mm .

Description

Multi Syringe Vial Filler is a specialized pharmaceutical packaging machine designed for the precise, aseptic filling of sterile liquids (such as vaccines, biologics, or injectables) into multiple vials, syringes, or cartridges simultaneously. It utilizes multiple syringe pumps or dosing mechanisms to ensure high accuracy, minimal waste, and compliance with strict regulatory standards like GMP (Good Manufacturing Practice). These systems are commonly used in pharmaceutical and biotech manufacturing for both small-batch clinical trials and large-scale commercial production. This machine uses multiple syringes (piston-type dosing system) mounted on an eccentric block for simultaneous multi-head filling. It is available in various configurations such as 2-head, 4-head, 8-head, or 12-head models, making it highly flexible for different production scales. The filling unit consists of high-quality syringes, nozzles, and non-return valves that ensure precise volume control with minimal variation.

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

Salient Features of Multi Syringe Vial Filler

Suitable for the filling Volume of 2ml to 250ml.
Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
No cross contamination.
Easy to validate filling system for small/large batch production.
All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.
Variable A.C. frequency drive for speed adjustment.

Digital Vial Counter for counting production output.
In-feed Turn Table/ Unscrambler for automatic feeding of objects.
On-line Mechanism.
“No Vial – No Filling” System.
“No Vial – Machine Stop” System.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Multi 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 Multi Syringe Vial Filler

Model	ALVF-40	ALVF-80	ALVF-120	ALVF – 250
Filling Heads	Two	Four	Eight	Twelve
Production Rate	Up to 40 Vials/Minute	Up to 80 Vials/Minute	Up to 150 Vials/Minute	Up to 250 Vials/Minute
Vial Diameter	15mm to 70mm	15mm to 70mm	15mm to 70mm	15mm to 70mm
Vial Height	25mm to 140mm	25mm to 140mm	25mm to 140mm	25mm to 140mm
Filling Precision	±1%	±1%	±1%	±1%
Power Required	1 H.P.	1.5 H.P.	2 H.P.	2 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2050mm (L) x 850mm (W) x 1700mm (H)	2200mm (L) x 850mm (W) x 1700mm (H)	3000mm (L) x 945mm (W) x 1700mm (H)	3500mm (L) x 945mm (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

Benefits of Multi Syringe Vial Filler

Efficiency and Flexibility: Supports multi-format production, ideal for high-mix, low-volume runs in personalized medicine.

Safety and Quality: Reduces human error, overfill waste, and particulate risks compared to manual filling.

Cost-Effectiveness: Optimizes API yield by precise dosing, especially for expensive drugs.

Key Components of Multi Syringe Vial Filler

Versatile Container Handling: Processes ready-to-use (RTU) nested vials, pre-sterilized syringes, and cartridges in a single unit, allowing quick format changes.

Filling Mechanism: Employs multiple rotary or peristaltic syringes for simultaneous dosing, reducing processing time while maintaining fill accuracy to ±0.5% or better.

Integrated Processes: Includes upstream functions like de-nesting and orientation, and downstream steps such as vacuum stoppering, plunger rod insertion, labeling, and inspection.

Aseptic Design: Minimizes contact points with containers to prevent contamination, often operating in isolators or RABS (Restricted Access Barrier Systems) for sterile environments.

Scalability: Benchtop models suit R&D or small batches, while larger systems handle high volumes.

FAQ for Multi Syringe Vial Filler

What is a Multi Syringe Vial Filler?

A Multi Syringe Vial Filler is a high-precision automatic liquid filling machine designed for aseptic filling of sterile injectable liquids into glass or plastic vials. It uses a multi-head piston-type syringe dosing system (2, 4, 8, or 12 heads) mounted on an eccentric block for simultaneous and accurate filling.

The machine is ideal for pharmaceuticals, biotech, veterinary, and cosmetic industries to fill vaccines, antibiotics, biologics, serums, and other sterile liquid formulations. It supports fill volumes from 2ml to 250ml with excellent accuracy while operating under Class 100 / ISO 5 laminar airflow and complying with cGMP and FDA standards.

What are the available models and production capacities?

We offer the following models in the ALVF series:

ALVF-40 (2 Head) — Up to 40–60 vials per minute
ALVF-80 (4 Head) — Up to 80–100 vials per minute
ALVF-120 (8 Head) — Up to 120–150 vials per minute
ALVF-250 (12 Head) — Up to 200–250 vials per minute

Actual output depends on vial size, fill volume, and liquid viscosity. The machine handles vial diameters from 15mm to 70mm and heights from 25mm to 140mm.

What is the filling accuracy and how does the multi syringe system work?

The Multi Syringe Vial Filler delivers high filling accuracy of ±0.5% to ±1%.

Working Principle: Sterilized vials are fed via a conveyor and positioned under the filling nozzles using a star wheel. Liquid is drawn from the product tank into AISI SS 316L syringes through silicon tubing. The diving nozzles lower into the vial to reduce foaming, dispense the precise volume (controlled by piston stroke length), and retract smoothly. A “No Vial – No Filling” system prevents wastage. Non-return valves ensure consistent dosing without variation.

Does the Multi Syringe Vial Filler include stoppering and support aseptic processing?

Yes. The machine features a compact monoblock design with integrated rubber stoppering (bunging) immediately after filling. Sterilized siliconized rubber stoppers are fed from a vibratory bowl and pressed firmly into the vial neck using a star wheel and spring-loaded roller.

Key aseptic features include:

All product contact parts in AISI SS 316L
Operation under laminar airflow
Optional nitrogen flushing
“No Vial – Machine Stop” safety system
Easy validation and minimal change parts

This minimizes product exposure and contamination risk, making it suitable for sterile injectable production.

What are the main advantages of the Multi Syringe Vial Filler?

The main advantages include:

Excellent filling accuracy (±0.5% to ±1%) with minimal product wastage
High production speed with multi-head simultaneous filling
Reduced labor costs and human error through full automation
Versatile for a wide range of vial sizes and fill volumes (2ml to 250ml)
Compact cGMP-compliant design with easy cleaning and quick format changeover
Safety features like safety clutch, overload protection, and “No Vial – No Filling” system
Easy integration into complete injectable lines (vial washing → sterilization → filling → stoppering → capping → labeling)
PLC + HMI control (optional) and digital vial counter for precise monitoring

It is highly suitable for both small-batch and large-scale sterile liquid production.

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