Vial Filling and Rubber Stoppering Machine

Description

Vial Filling and Rubber Stoppering Machine is an automated pharmaceutical packaging equipment designed for the precise filling of injectable liquids into glass vials and subsequent sealing with rubber stoppers. This machine ensures sterility, prevents contamination, and maintains product integrity by accurately dosing liquids and securely applying stoppers, making it essential for high-volume production in the pharmaceutical, biotechnology, and healthcare industries. It operates on a volumetric principle, using pumps like piston or peristaltic types to achieve filling accuracy of ±1%, and is compliant with standards such as cGMP.

Vial Loading: Empty, sterilized vials are fed via the infeed turntable onto a conveyor.

Filling Process: Vials move to the filling station, where nozzles descend to inject the exact volume of liquid. The synchronized motion filling system allows nozzles to track vials without stopping the line, enhancing speed.

Stoppering Process: Filled vials transfer to the stoppering station, where a vibrating bowl dispenses oriented rubber stoppers into a chute. Vials are held by a rotating star wheel, picking up stoppers that are then pressed down by rollers.

Output: Stoppered vials exit via the outfeed turntable for further processes like capping or labeling.

Salient Features of Vial Filling and Rubber Stoppering Machine

No cross contamination.
Suitable for the filling Volume of 2ml to 250ml.
Piston pump/Peristaltic pump aseptic filling.
Filling with accuracy of ±0.5-1%.
Easy to validate filling system for small/large batch production.
All Contact Parts Made from S.S 316L & framework by S.S. 304.
Variable A.C. frequency drive for speed adjustment.
Digital Vial Counter for counting production output.
In-feed Turn Table/ Unscrambler for automatic feeding of objects.
On-line Mechanism.
“No Vial – No Filling” system.
“No Vial – Machine Stop” system.
IQ/OQ documentation can be provided to comply vial filling machine validation process.
PLC with Graphical User Interface. (Optional)
PRIME is a distinctive feature that allows you to quickly suck filling material from the storage tank to the nozzle end. This feature is also beneficial for cleaning the filling line (silicon tubing) and filling the peristaltic pump in both directions.
PLC alarms for “No Vial, Machine Stop” and “No Vial, No Bung.”
For daily track reports and planning, a password-protected production counter is provided.
The errors can be recognized on the touch screen HMI of the PLC and readily attended to.

The machine can use the PRIME function for all peristaltic pumps together or for individual peristaltic pump.
Filling is done with a specifically built filling peristaltic pump which has CIP and SIP ability.
Individual pumps may be calibrated and adjusted for the desired volume using a simple PLC.
Because of a particularly built peristaltic pump with suck back capability, oil-based materials can also be run without dripping.
Each filling head may operate independently, allowing the machine to operate constantly without sacrificing significant production.
Bung orientation bowl and discharge chute with built-in vibrator. For use with wet bungs, we offer bung orienter bowl and chute with Teflon coating.
Bungs are held in a specifically designed vacuum bung hold disc, which then discharges the bung evenly onto the vial. The bung pressing roller evenly presses the bungs.
Half stoppering can be done with the same Rubber bunging machine assembly.
Each filling head may operate independently, allowing the machine to operate constantly without sacrificing significant production.
For varied sizes of vials and filling volumes, no change parts are necessary.
Because mechanical parts like syringe sets, Teflon seals, gears, and chains are rarely used, there is relatively little product variation over time.
PLC with simple controls for volume and speed adjustments.
The entire assembly can be adjusted upwards and lower to accommodate different heights of vials.
To avoid the negative effects of the electric supply, the machine is supplied with an isolated power source.
Well known mechanical components such as FESTO/Janatics pneumatics and CE approved electrical/electronic components such as Bonfiglioli/Crompton AC motors, Allen Bradley drives, PLC & HMI Touch screen, Sensors, MCB’s, relays, and other components.

Working Principle of Vial Filling and Rubber Stoppering Machine

The incoming dry vials (sterilized and siliconised) are fed through the in-feed turn table and suitably guided on the moving Stainless Steel slat conveyor belt at the required speed of the correct placement below filling unit.

The filling unit consists syringes & nozzles. Syringes are made of Stainless Steel 316L material for cGMP compliance. Vials stop below filling unit with centering of filling nozzles, during stoppage nozzles discharge pre determined liquid into vials. Duly filled vials delivered on stoppering unit which is mounted on same platform.

Stoppering Unit consist Bowl and Chute designed for desired stopper / bung size. Stoppers are stored in vibratory bowl and delivered to the vial through delivery chute. Vibratory bowl is equipped with special vibrator motor. Stoppers travel in vibratory bowl support guide through vibration. There is arrangement in the bowl in which wrong position stopper get rejected in travelling and only correct position of stopper get into chute. Further stoppers hold at delivery point of chute through spring which collected one by one by vial in traveling below the chute. Further there is one Stainless Steel 304 roller installed to press the stoppers. Vial transfer below the wheel in which get stoppered.

Duly stoppered vials further move on conveyor & collected on out feed turn table (optional) or on to conveyor of vial aluminum cap sealing machine for cap sealing operations.

Technical Specification of Vial Filling and Rubber Stoppering Machine

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
Input Specification
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 Filling and Rubber Stoppering Machine

High Filling Accuracy and Consistency

Enhanced Sterility and Product Safety

Increased Production Speed and Efficiency

Reduced Contamination Risk and Easy Validation

Cost-Effectiveness and Versatility

Key Components of Vial Filling and Rubber Stoppering Machine

Infeed and Outfeed Systems: Built-in turntables with individual drives for smooth vial entry and exit, often including a Delrin slat conveyor to prevent sticking and ensure consistent movement.

Filling Station: Equipped with multiple heads (e.g., 2, 4, 8, or 12) for simultaneous filling. Nozzles move vertically via cam mechanisms for precise dosing, with options for nitrogen flushing before and after filling to minimize oxidation. A “No Vial, No Fill” system prevents liquid wastage.

Stoppering Unit: Features a vibrating bowl and Teflon-coated chute for orienting and feeding rubber stoppers. Vacuumetric or pneumatic systems pick and press stoppers uniformly using spring-loaded rollers, supporting both full and half-stoppering.

Safety and Construction: All liquid-contact parts are made of stainless steel (SS 316L) for easy sterilization and autoclaving. The machine includes acrylic safety covers, laminar airflow for cleanroom compatibility, and PLC/HMI controls for automation.

Drive System: Powered by high-quality gear motors and AC drives for vibration-free operation, with minimal oil leakage.

FAQ for Vial Filling and Rubber Stoppering Machine

What is a Vial Filling and Rubber Stoppering Machine and what does it do?

The Vial Filling and Rubber Stoppering Machine is a fully automatic monoblock system designed to fill sterilized vials with liquid injectables and immediately apply rubber stoppers (bungs) in a single continuous operation. It uses a volumetric piston or peristaltic pump for precise filling, followed by an automatic stoppering unit with a vibratory bowl, chute, and pressing rollers. The machine ensures high sterility, minimal contamination, and compliance with cGMP standards, making it ideal for pharmaceutical and biotech production of vaccines, serums, antibiotics, and other sterile liquids.

What is the production capacity of the Vial Filling and Rubber Stoppering Machine?

Our Vial Filling and Rubber Stoppering Machine is available in four models with the following outputs:

ALVF-40 (2 filling heads): Up to 40 vials per minute
ALVF-80 (4 filling heads): Up to 80 vials per minute
ALVF-120 (8 filling heads): Up to 150 vials per minute
ALVF-250 (12 filling heads): Up to 250 vials per minute

The 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 Filling and Rubber Stoppering Machine 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 for different vial sizes and heights is easy with adjustable assembly and minimum or no change parts required in many cases. The “No Vial – No Filling” and “No Vial – Machine Stop” systems prevent wastage and ensure smooth operation.

How does the Vial Filling and Rubber Stoppering Machine ensure sterility and product quality?

Sterility and quality are maintained through:

Operation under Laminar Air Flow (Class 100) with optional inbuilt LAF.
All product contact parts made of S.S. 316L; framework in S.S. 304.
Nitrogen flushing (optional) before and after filling to minimize oxidation.
Automatic rubber stoppering with half-stoppering capability and vacuum bung hold disc.
Easily removable contact parts for autoclaving/sterilization and CIP/SIP capable options.

Additional safety features include acrylic covers, safety clutch to avoid vial breakage, and PLC alarms, ensuring compliance with USFDA, cGMP, and WHO guidelines.

What are the power requirements and key features of the Vial Filling and Rubber Stoppering Machine?

Power requirements are model-specific and energy-efficient:

ALVF-40: 1 HP
ALVF-80: 1.5 HP
ALVF-120 & ALVF-250: 2 HP

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

Key features include variable AC frequency drive for speed control, digital vial counter, touch screen HMI (optional), PRIME feature for line cleaning, independent filling heads, password-protected counters, and seamless integration with vial washing, sterilizing, capping, and labeling machines for a complete production line.

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