The Two Head Vial Filling Machine, often referred to as a Two Head Automatic Vial Filling and Rubber Stoppering Machine, is a compact, semi-automatic or fully automatic pharmaceutical packaging equipment designed primarily for filling sterile injectable liquids into glass vials and then sealing them with rubber stoppers. This machine is ideal for small to medium batch productions in sterile environments, such as under laminar airflow protection, ensuring compliance with cGMP standards and minimizing contamination risks. It features two filling heads for efficient operation, handling round vials typically ranging from 2ml to 50ml in size.
Vial Filling Machine Video
Key Features
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Construction and Materials: Built with stainless steel for durability, corrosion resistance, and easy cleaning. The machine often includes a matt-finished exterior to reduce glare in cleanrooms.
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Filling Mechanism: Utilizes volumetric piston pumps or syringes with adjustable stroke lengths for precise filling volumes. Nozzles move up and down via a cam mechanism to prevent splashing and foaming.
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Stoppering System: Integrated rubber stoppering unit presses 13mm or 20mm rubber stoppers with a fixed roller or vacuum hold disc, ensuring secure sealing without vial breakage.
- Safety and Efficiency Features:
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“No Vial, No Fill” sensor to prevent liquid wastage.
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Nitrogen flushing for oxygen-sensitive products.
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Minimal distance between filling and stoppering units to reduce exposure to contaminants.
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Easy changeover for different vial sizes without major adjustments.
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Controls: Equipped with a compact electrical panel, AC drive for speed control, and optional touchscreen interface for user-friendly operation.
Working Principle
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Vial Feeding: Sterilized and siliconized vials are fed via an unscrambler or turntable onto a Delrin slat conveyor belt, positioned accurately under the filling heads using a star wheel.
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Filling: The two heads simultaneously fill liquid into vials held by the star wheel. Syringes (glass or SS) draw and dispense the exact volume, with nozzles descending during filling and ascending afterward.
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Stoppering: Filled vials move to the stoppering station, where rubber stoppers are oriented via a vibrating bowl and chute, then pressed vertically onto the vials.
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Discharge: Sealed vials are ejected onto the conveyor for further capping (if needed) or packaging. The entire process operates in a sterile zone, often with laminar airflow.
This bottom-up filling technique handles both low- and high-viscosity liquids efficiently, with independent head operation allowing continuous production even if one head encounters an issue.
Applications
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Pharmaceuticals: Filling injectables, syrups, or ophthalmic solutions.
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Biotech and Cosmetics: Handling essential oils, perfumes, or sterile serums.
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Food and Lab Use: Small-batch liquid packaging in controlled environments.
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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