A 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 Filler Video
Key Features
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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.
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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.
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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.
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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.
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Capacity and Speed: Fills 20–60 vials per minute, handling 2–50 mL vials. Suitable for aqueous solutions to light oils.
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Controls and Safety: Touchscreen interface for easy operation, with optional laminar airflow integration. Designed for aseptic processing, reducing contamination risks.
Operational Process
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Vial Infeed: Sterilized vials enter via conveyor and are oriented by a turntable or unscrambler.
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Filling: Vials are gripped by the star wheel and positioned under the two filling nozzles, which descend to fill precisely before ascending.
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Stoppering: Filled vials move to the stoppering station, where rubber stoppers are picked and pressed in.
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Output: Completed vials exit on the conveyor for downstream capping, labeling, or inspection.
Salient Features of Vial Filling Machine
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Suitable for the filling Volume of 2ml to 250ml.
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Piston pump/Peristaltic pump aseptic filling.
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Filling accuracy of ±0.5% to ±1%.
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No cross contamination.
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Easy to validate filling system for small/large batch production.
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All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 304.
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Variable A.C. frequency drive for speed adjustment.
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Digital Vial Counter for counting production output.
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In-feed Turn Table/ Unscrambler for automatic feeding of objects.
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On-line Mechanism.
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“No Vial – No Filling” System.
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“No Vial – Machine Stop” System.
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IQ/OQ documentation can be provided.
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PLC system with Graphical User Interface. (Optional)
Process Operation of Automatic 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 Filling Machine
| 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.
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