Vial Liquid Filling Machine

Q: Which vial sizes can the Vial Liquid Filling Machine handle?

The machine handles a wide range of vial sizes: Diameter : 15mm to 70mm Height : 25mm to 140mm It supports fill volumes from 2ml to 250ml . The versatile design allows easy adjustment for different vial dimensions with minimum changeover parts, making it suitable for both small-batch and large-scale sterile liquid production.

Q: What are the power requirements and key features of the Vial Liquid Filling Machine?

Power requirements are model-specific: 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 a digital vial counter, variable AC frequency drive for speed control, PLC with HMI (optional), safety sensors, compact footprint, and easy integration with vial washing, sterilizing, stoppering, and sealing machines for a complete production line.

Description

Vial Liquid Filling Machine is a specialized piece of automated equipment primarily used in the pharmaceutical, biotechnology, and healthcare industries to precisely fill small glass or plastic vials with liquid substances, such as injectable drugs, vaccines, or sterile solutions. Vial Liquid Filling Machine ensure high accuracy, sterility, and efficiency, minimizing contamination risks and product waste while complying with strict regulatory standards like cGMP, FDA, and ISO guidelines. They are essential for high-volume production, handling viscosities from low to high, and accommodating vial sizes typically ranging from 2 ml to 100 ml.

Vial Feeding: Empty vials are loaded and aligned on a conveyor.

Preparation: Vials pass through washing/sterilization under laminar airflow in a Class 100 cleanroom environment.

Filling: Needles or nozzles dispense the liquid at controlled speeds; nitrogen flushing may be added to displace oxygen and extend shelf life.

Closing: Stoppers are inserted, and caps are applied, often with 100% in-process verification.

Output: Filled vials are ejected for further processing at rates from 100–600 vials per minute, depending on the model.

Salient Features of Vial Liquid Filling Machine

Easy to validate filling system for small/large batch production.
In-feed Turn Table/ Unscrambler attached with the machine for automatic feeding of vials.
Filling accuracy of ±1% depends upon fluid & vial types.
Machine equipped with pre-warming station.
PLC system with Graphical User Interface. (Optional)
All Contact Parts Made from AISI SS 316L & framework by AISI SS 304.

Compact footprint cGMP complied models.
2ml to 250ml fill dosage compatibility.
Variable A.C. frequency drive for speed adjustment.
Digital Vial Counter for counting production output.
On-line Mechanism.
IQ/OQ validation documents can be offered.
No cross contamination.

Working Principle of Vial Liquid Filling 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 Liquid Filling 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
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 Liquid Filling Machine

Precision and Compliance: Ensures exact dosing (±0.05–0.5%) and sterility, reducing rejects via features like re-stoppering.

Efficiency: Boosts throughput while integrating with downstream processes like freeze-drying for extended shelf life.

Versatility: Handles various liquids (e.g., oncology drugs, vaccines) and formats in cleanrooms.

Safety: Includes safeguards like no-bottle sensors and HEPA filtration to protect operators and products.

Key Components of Vial Liquid Filling Machine

Vial Liquid Filling Machines are modular and often integrated into complete production lines. Common components include:

Unscrambler and Conveyor: Orient and transport vials to the filling station via a belt or rotary system.

Washing and Sterilizing Stations: Clean vials internally and externally using deionized water, air drying, and depyrogenation with hot air or steam to remove endotoxins.

Filling Heads/Nozzles: Servo-controlled peristaltic, piston, or time-pressure pumps deliver precise volumes without contact to avoid contamination.

Stoppering and Capping Unit: Inserts rubber stoppers and applies aluminum seals or crimps for secure closure.

Inspection Systems: Inline sensors for weight checking, leak detection, particle inspection, and container integrity.

Control Systems: PLC-based with touchscreens for real-time monitoring, recipe storage, and integration with lyophilizers or labeling machines.

FAQ for Vial Liquid Filling Machine

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

The Vial Liquid Filling Machine is a fully automatic system designed to precisely fill sterilized glass or plastic vials with liquid injectables, vaccines, serums, or other pharmaceutical solutions. It uses a volumetric piston filling principle with SS 316L syringes and nozzles. Vials are fed via an in-feed turn table or unscrambler onto a Delrin slat conveyor, filled accurately, and then transferred for stoppering. The machine ensures high sterility, minimal contamination, and compliance with cGMP standards, making it ideal for pharmaceutical and biotech production lines.

What is the production capacity of the Vial Liquid Filling Machine?

Our Vial Liquid Filling 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, liquid viscosity, and fill volume (2ml to 250ml). All models deliver consistent filling accuracy of ±1%.

Which vial sizes can the Vial Liquid Filling Machine handle?

The machine handles a wide range of vial sizes:

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

It supports fill volumes from 2ml to 250ml. The versatile design allows easy adjustment for different vial dimensions with minimum changeover parts, making it suitable for both small-batch and large-scale sterile liquid production.

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

Sterility and quality are maintained through:

Operation under Laminar Air Flow in a Class 100 cleanroom environment.
“No Vial – No Filling” sensor to prevent wastage and contamination.
Nitrogen flushing (optional) to displace oxygen and extend product shelf life.
All product contact parts made of AISI SS 316L (syringes & nozzles), with framework in SS 304.
Pre-warming station and precise volumetric filling with non-return valves.

The machine minimizes cross-contamination and is easy to validate with IQ/OQ documentation, meeting USFDA, cGMP, and ISO guidelines.

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

Power requirements are model-specific:

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 a digital vial counter, variable AC frequency drive for speed control, PLC with HMI (optional), safety sensors, compact footprint, and easy integration with vial washing, sterilizing, stoppering, and sealing machines for a complete production line.

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Vial Liquid Filling Machine

Description

Salient Features of Vial Liquid Filling Machine

Working Principle of Vial Liquid Filling Machine

Technical Specification of Vial Liquid Filling Machine

Types of Vial Filling Machine

Applications of Vial Filling Machine

Benefits of Vial Liquid Filling Machine

Precision and Compliance: Ensures exact dosing (±0.05–0.5%) and sterility, reducing rejects via features like re-stoppering.

Efficiency: Boosts throughput while integrating with downstream processes like freeze-drying for extended shelf life.

Versatility: Handles various liquids (e.g., oncology drugs, vaccines) and formats in cleanrooms.

Safety: Includes safeguards like no-bottle sensors and HEPA filtration to protect operators and products.

Key Components of Vial Liquid Filling Machine

FAQ for Vial Liquid Filling Machine

Countries We Export to

Partner with Industry Experts

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