A PLC Based Vial Filler is a fully automated, high-precision liquid filling system designed for pharmaceutical, biotechnology, and cosmetic industries to fill sterile or non-sterile liquids into glass or plastic vials with exceptional accuracy, repeatability, and compliance with cGMP, FDA, and 21 CFR Part 11 standards.
Vial Filler Machine Video
Key Features of Vial Filler
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Control System: Advanced Programmable Logic Controller (PLC) combined with Human Machine Interface (HMI) or SCADA for real-time monitoring, recipe management, precise control of filling volume, speed, and process parameters.
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Filling Principle: Peristaltic pumps, servo-driven piston pumps, or time-pressure technology ensuring ±0.5% or better filling accuracy.
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Nozzle System: Diving nozzle or bottom-up filling mechanism to minimize foaming and contamination, with no-vial-no-fill and no-stopper-no-fill sensors.
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Sterility & Cleanliness: Designed for laminar air flow compatibility, available with isolator or RABS integration, CIP/SIP-capable options.
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Vial Transport: Servo-controlled or mechanical starwheel indexing for gentle and precise vial handling.
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Safety & Interlocks: Automatic rejection of under/over-filled, missing stopper, or damaged vials; full audit trail and electronic batch reporting.
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Speed: 30–400 vials per minute depending on configuration.
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Optional Modules: Integrated stoppering, capping/crimping, labeling, and tray loading stations.
Advantages of PLC Control:
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Easy recipe storage and recall (up to hundreds of products)
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Precise servo synchronization
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Remote diagnostics and troubleshooting
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Data logging and compliance with Annex 11 & 21 CFR Part 11
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High uptime and minimal changeover time
Widely used for injectables, vaccines, ophthalmics, biologics, and high-value formulations requiring maximum accuracy and contamination control.
* 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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