Two Head Vial Filler

Q: What is a Two Head Vial Filler?

The Two Head Vial Filler (Model: ALVF-40) is a compact, cGMP-compliant monoblock machine designed for precise aseptic filling and rubber stoppering of sterile injectable liquids into glass vials. It features two filling heads that work simultaneously, enabling higher production output while maintaining excellent accuracy. The machine uses piston or peristaltic pumps with diving nozzles for bottom-up filling, minimizing foaming and splashing. It is ideal for medium batch production in sterile environments under laminar airflow.

Q: What is the production capacity and vial size range of the Two Head Vial Filler?

The Two Head Vial Filler has a production capacity of up to 40 vials per minute . It can handle vial diameters from 15mm to 70mm and heights from 25mm to 140mm , with filling volumes ranging from 2ml to 250ml . This makes it highly suitable for small to medium batch sizes in pharmaceutical and biotech production.

Q: What is the filling accuracy of the Two Head Vial Filler?

The machine offers a filling accuracy of ±1% (achievable up to ±0.5% depending on liquid characteristics and volume). It includes a “No Vial – No Filling” and “No Vial – Machine Stop” system to prevent product wastage and ensure consistent dosing. All product contact parts are made of Stainless Steel 316L , ensuring compliance with sterile injectable standards.

Q: What are the advantages of using a Two Head Vial Filler?

The main advantages are: Higher production speed (up to 40 vials/min) compared to single-head machines Better throughput with a still-compact footprint Reduced cycle time and improved efficiency for medium batches Cost-effective upgrade from single-head systems Consistent accuracy with minimal wastage Easy validation and maintenance for small to large batch production It is widely used in the pharmaceutical, biotech, cosmetic, and chemical industries for filling vaccines, antibiotics, biologics, suspensions, and other sterile liquids.

Description

Two Head Vial Filler is a compact, automated pharmaceutical machine designed primarily for the precise filling and rubber stoppering of injectable liquids into glass vials. It is widely used in sterile environments, such as cleanrooms under laminar flow protection, to ensure compliance with cGMP standards for pharmaceutical and biotechnology production. This equipment is ideal for small to medium batch sizes, offering efficiency without the complexity of larger multi-head systems.

Vial Infeed: Sterilized vials enter via conveyor and are oriented by a turntable or unscrambler.

Filling: Vials are gripped by the star wheel and positioned under the two filling nozzles, which descend to fill precisely before ascending.

Stoppering: Filled vials move to the stoppering station, where rubber stoppers are picked and pressed in.

Output: Completed vials exit on the conveyor for downstream capping, labeling, or inspection.

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

Salient Features of Two Head Vial Filler

Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
No cross contamination.
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 Vial – Machine Stop” System.
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 Two Head 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 Two Head Vial Filler

Model	ALVF-40
Filling Heads	Two
Production Rate	Up to 40 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	1 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2050mm (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 Two Head Vial Filler

Higher Production Efficiency

Improved Throughput with Compact Design

Better Consistency and Accuracy

Cost-Effective Upgrade

Reduced Cycle Time

Easier Maintenance and Operation

Key Components of Two Head Vial Filler

Construction and Materials: Built with a stainless steel (SS) frame and finish for durability and easy cleaning. Critical components like syringes and nozzles are made from AISI SS 316L to prevent corrosion and contamination.

Filling Mechanism: Equipped with two volumetric filling heads using precision syringes and nozzles. The nozzles feature cam-driven up-and-down movement for bottom-up filling, minimizing foaming, splashing, and product waste. It supports pre- and post-gassing for sterile operations.

Stoppering System: Integrated rubber stoppering unit with a star wheel that holds vials securely during pressing. A spring-loaded roller applies rubber stoppers (up to 20 mm diameter with ±1% accuracy) from a chute.

Vial Handling: Incoming sterilized and siliconized vials are fed via an unscrambler to a Delrin slat conveyor belt. A star wheel positions vials accurately under the heads, delivering two vials at a time post-filling for stoppering.

Capacity and Speed: Fills 20–60 vials per minute, handling 2–50 mL vials. Suitable for aqueous solutions to light oils.

Controls and Safety: Touchscreen interface for easy operation, with optional laminar airflow integration. Designed for aseptic processing, reducing contamination risks.

FAQ for Two Head Vial Filler

What is a Two Head Vial Filler?

The Two Head Vial Filler (Model: ALVF-40) is a compact, cGMP-compliant monoblock machine designed for precise aseptic filling and rubber stoppering of sterile injectable liquids into glass vials.

It features two filling heads that work simultaneously, enabling higher production output while maintaining excellent accuracy. The machine uses piston or peristaltic pumps with diving nozzles for bottom-up filling, minimizing foaming and splashing. It is ideal for medium batch production in sterile environments under laminar airflow.

What is the production capacity and vial size range of the Two Head Vial Filler?

The Two Head Vial Filler has a production capacity of up to 40 vials per minute.

It can handle vial diameters from 15mm to 70mm and heights from 25mm to 140mm, with filling volumes ranging from 2ml to 250ml. This makes it highly suitable for small to medium batch sizes in pharmaceutical and biotech production.

What is the filling accuracy of the Two Head Vial Filler?

The machine offers a filling accuracy of ±1% (achievable up to ±0.5% depending on liquid characteristics and volume). It includes a “No Vial – No Filling” and “No Vial – Machine Stop” system to prevent product wastage and ensure consistent dosing.

All product contact parts are made of Stainless Steel 316L, ensuring compliance with sterile injectable standards.

What are the key features of the Two Head Vial Filler?

Key features include:

Dual filling heads for higher throughput
“No Vial – No Filling” and “No Vial – Machine Stop” mechanisms
Digital vial counter for accurate production monitoring
Variable AC frequency drive for speed control
Easy format changeover and quick cleaning
Optional PLC system with HMI (Graphical User Interface)
IQ/OQ documentation support
Compact design with SS 316L contact parts and SS 304 framework

The machine supports piston or peristaltic pump filling and is designed for no cross-contamination.

What are the advantages of using a Two Head Vial Filler?

The main advantages are:

Higher production speed (up to 40 vials/min) compared to single-head machines
Better throughput with a still-compact footprint
Reduced cycle time and improved efficiency for medium batches
Cost-effective upgrade from single-head systems
Consistent accuracy with minimal wastage
Easy validation and maintenance for small to large batch production

It is widely used in the pharmaceutical, biotech, cosmetic, and chemical industries for filling vaccines, antibiotics, biologics, suspensions, and other sterile liquids.

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