Glass vials are filled and stoppered using the Vial Filler and Capper (automated vial filler), which includes vial filling machines. For precise filling, the machine has a specifically made SS 316L filling pump. The turntable, stainless steel slat conveyor belt, and special eccentric pre-gassing, filling, and post-gassing components make up the vial filler and sealer machine. Easy-to-reach compact panels, non-toxic synthetic rubber tubing, and extremely effective and precisely constructed stainless steel 316L syringes.
The risk of contamination is decreased by the small distance between vial filling and stoppering equipment. The devices are made to be used under laminar flow protection and in a sterile environment. Dead ends and hard-to-clean areas have been removed from the un-scrambler itself. Vials with dosages ranging from 2 ml to 250 ml can be filled by an injectable liquid filling machine.
Vial Filler and Capper Machine Video
Types of Vial Filler and Capper Machines
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Vial Filler and Capper Machine
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Monoblock Vial Filler Capper
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Vial Filling and Sealing Machine
Key Features & Functions:
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Peristaltic or piston pump filling for high-accuracy dosing (±0.5% or better) with no cross-contamination
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Vial infeed via turntable, conveyor, or unscrambler
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No-vial-no-fill / no-vial-no-stopper / no-stopper-no-cap sensors for 100% process control
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Automatic stopper insertion (rubber stoppers or lyophilization stoppers)
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Aluminum crimp cap or screw cap application with precise torque control
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Optional nitrogen purging before and after filling (for oxygen-sensitive products)
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Laminar air flow (LAF) or isolator compatibility for aseptic environments
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cGMP-compliant design with 316L stainless steel contact parts and easy changeover (tool-free in many models)
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PLC + HMI control with recipe management, batch reporting, and 21 CFR Part 11 compliance options
Typical Applications:
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Injectable solutions (antibiotics, vaccines, biologics)
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Ophthalmic products
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Diagnostic reagents
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High-value small-batch production
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Lyophilized products (with full/semi-stoppering)
Salient Features of Vial Filler and Capper
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Compact footprint cGMP complied models.
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2ml to 250ml fill dosage compatibility.
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Filling accuracy of ±1% depends upon fluid & vial types.
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“No Vial – No Filling” system feature.
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In-feed Turn Table/ Unscrambler attached with the machine for automatic feeding of vials.
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All Contact Parts Made from AISI SS 316L & framework by AISI SS 304.
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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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Variable A.C. frequency drive for speed adjustment.
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Digital Vial Counter for counting production output.
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On-line Mechanism.
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IQ/OQ validation documents can be offered.
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PLC system with Graphical User Interface. (Optional)
Process Operation of Vial Filling and Capping Machine
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 Vial Filler and Capper
| 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.
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