Vial Filler and Capper

Q: Which vial sizes can the Vial Filler and Capper handle?

The machine handles a wide range of vial sizes: Vial Diameter : 15mm to 70mm Vial Height : 25mm to 140mm It supports fill volumes from 2ml to 250ml . Changeover between different vial sizes is quick with minimum change parts. The versatile design makes it suitable for both small-batch and large-scale sterile liquid production.

Description

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.

Salient Features of Vial Filler and Capper

Compact footprint cGMP complied models.
2ml to 250ml fill dosage compatibility.
No cross contamination.
“No Vial – No Filling” system feature.
IQ/OQ validation documents can be offered.
On-line Mechanism.
PLC system with Graphical User Interface. (Optional)

Filling accuracy of ±1% depends upon fluid & vial types.
Easy to validate filling system for small/large batch production.
Variable A.C. frequency drive for speed adjustment.
Digital Vial Counter for counting production output.
All Contact Parts Made from AISI SS 316L & framework by AISI SS 304.
In-feed Turn Table/ Unscrambler attached with the machine for automatic feeding of vials.

Working Principle of Vial Filler and Capper

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.

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

Benefits of Vial Filler and Capper

Three-in-One Operation for Maximum Efficiency

High Filling Accuracy and Consistent Quality

Superior Sterility and Contamination Control

High Production Output

Cost-Effective and Easy Maintenance

Easy Line Integration and Regulatory Compliance

Key Components of Vial Filler and Capper

Peristaltic or piston pump filling for high-accuracy dosing (±0.5% or better) with no cross-contamination

Vial infeed via turntable, conveyor, or unscrambler

No-vial-no-fill / no-vial-no-stopper / no-stopper-no-cap sensors for 100% process control

Automatic stopper insertion (rubber stoppers or lyophilization stoppers)

Aluminum crimp cap or screw cap application with precise torque control

Optional nitrogen purging before and after filling (for oxygen-sensitive products)

Laminar air flow (LAF) or isolator compatibility for aseptic environments

cGMP-compliant design with 316L stainless steel contact parts and easy changeover (tool-free in many models)

PLC + HMI control with recipe management, batch reporting, and 21 CFR Part 11 compliance options

FAQ for Vial Filler and Capper

What is a Vial Filler and Capper and what does it do?

The Vial Filler and Capper is a fully automatic monoblock machine designed to perform three critical operations in one compact unit: liquid filling, rubber stoppering, and aluminum capping of sterilized vials. It is ideal for sterile injectable production such as vaccines, antibiotics, and serums. The machine ensures high precision, minimal contamination, and compliance with cGMP standards, making it highly efficient for pharmaceutical and biotech manufacturers.

What is the production capacity of the Vial Filler and Capper?

Our Vial Filler and Capper is available in multiple models with the following outputs:

2 Head: Up to 40–60 vials per minute
4 Head: Up to 80–100 vials per minute
8 Head: Up to 120–150 vials per minute
12 Head: Up to 200–250 vials per minute

Actual speed depends on vial size, fill volume (2ml to 250ml), and liquid viscosity. All models deliver consistent filling accuracy of ±1%.

Which vial sizes can the Vial Filler and Capper handle?

The machine handles a wide range of vial sizes:

Vial Diameter: 15mm to 70mm
Vial Height: 25mm to 140mm

It supports fill volumes from 2ml to 250ml. Changeover between different vial sizes is quick with minimum change parts. The versatile design makes it suitable for both small-batch and large-scale sterile liquid production.

How does the Vial Filler and Capper ensure sterility and product quality?

Sterility and quality are maintained through:

Operation under Laminar Air Flow (Class 100) environment.
“No Vial – No Filling” system to prevent wastage and contamination.
Immediate rubber stoppering followed by precise aluminum capping to minimize exposure.
All product contact parts made of SS 316L.
Optional nitrogen flushing before and after filling.

The monoblock design reduces handling and contamination risk while meeting strict USFDA, WHO, and cGMP guidelines for injectable filling and sealing.

What are the power requirements and key features of the Vial Filler and Capper?

Power requirements are model-specific:

Smaller models: 1.5 – 2 HP
Larger models: 2 – 3 HP

(All models typically operate on 440 Volts, 3 Phase, 50 Hz – customizable as per your country’s voltage.)

Key features include:

Compact monoblock design (Filling + Stoppering + Capping)
Variable AC frequency drive for speed control
Digital vial counter and optional PLC + HMI
Safety clutch to avoid vial breakage
Easy integration with vial washing, sterilizing, and labeling machines
Quick changeover and low maintenance

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