Vial Powder 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 Powder Filling Machine (also known as an Injectable Powder Filling Machine or Sterile Powder Filler) is a specialized piece of pharmaceutical equipment designed for the precise, automated filling of sterile dry powders into glass vials. These machines are essential in the production of injectable medications, such as antibiotics, vaccines, and lyophilized drugs, ensuring sterility, accuracy, and compliance with Good Manufacturing Practices (GMP) and FDA standards. They operate in aseptic environments to minimize contamination risks and are often integrated into complete vial processing lines that include washing, sterilization, stoppering, capping, and labeling.

Vial Preparation: Empty sterile glass vials enter via infeed turntable after upstream washing and depyrogenation (using hot air ovens or tunnels).

Powder Filling: Vials are positioned under the powder wheel. Vacuum/pressure draws and dispenses a precise powder dose into each vial. Agitators ensure consistent flow.

Stoppering: A vibrating feeder drops rubber stoppers, which are pressed into place.

Outfeed and Integration: Filled and stoppered vials exit to capping/sealing stations. The entire line can achieve up to 19,200 vials per hour in high-speed models.

Inspection: Inline checks for fill weight, stopper placement, and defects.

Salient Features of Vial Powder Filling Machine

Compact cGMP model.
“No Vial, No Filling” system eliminates wastage of costly powder.
Individual drive for the filling & sealing to match the speed of filling & sealing.
Safety clutch system to avoid Vial breakage.
Variable AC Frequency Drive for speed adjustment.
Digital counter for counting production output.

Multiple Dosing System.
Built-in Rubber Stoppering Unit saves lot of space in the Sterile Area & reduces the length of Laminar Flow.
High Volumetric Filling Accuracy of ±2% of uniform density Injectable powder can be ensured by setting the depth of piston in the port of powder wheel.
All motors are provided with appropriate contractors and relays for the protection against any overload or jamming.
All contact parts are easily removable for mandatory Autoclaving/ Sterilization.

Working Principle of Vial Powder Filling Machine

The sterilized powder is stored in powder hopper is agitated by pair of mechanical agitators for maintaining consistency and uniform bulk density. The powder wheel having eight ports rotates at the pre determined speed below the powder hopper with practically no clearance. Powder wheel consist of Piston in each port and behind the powder wheel vacuum plate is provided there is no clearance between powder wheel and vacuum plate due to back spring pressure. Precise volume of powder is sucked in to the port of powder wheel during vacuum according to the piston length different fill size can be achieved. The excess powder is doctored off by a doctor blade. Doctor blades can be adjusted from outside also without removing powder hopper. When powder wheel indexes further and remain in the port due to the vacuum till it reaches just vertically above the container. The time dose of Compressed air (Nitrogen Gas), sterilized low pressure air sequentially flushes out powder from the port of powder wheel in to the container one by one. The filled containers are immediately separated on the conveyor by vial separator and moves further for stoppering operation. (Different grooves separator can be used which depends on the container diameter or multiple dosing systems). The sterilized, siliconised, rubber stoppers stored in the vibrator bowl moves to vibratory bowl and stacked vertically in the rubber stopper chute. The container is hold firmly between pair or timing belt to pickup rubber stopper from exit end of the chute. Further the container is passed between two pressing roller for tight fit fixing of rubber stopper.

Technical Specification of Vial Powder Filling Machine

Models	APF 12S	APF 12D
Production Output	Up to 100 vials/minute	Up to 200 vials/minute
Fill Volume	50 mg. to 10grams	50 mg. to 10 grams
Vial Size	5ml to 250ml	5ml to 250ml
Filling Accuracy	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder	± 2 – 3% in single dosing depending upon consistency and uniformity of bulk density of Injectable Powder
Power Load	3.5 H. P.	4.5 H. P.
Overall Dimension	2600mm (L) X 1100mm (W) X 1800mm (H) approx.	3000mm (L) X 1100mm (W) X 1800mm (H) approx.
Net Weight	500 kgs. approx.	700 kgs. approx.
Gross Weight	750 kgs. approx.	950 kgs. approx.

* 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 Powder Filling Machine

Industries: Primarily pharmaceuticals, biotech, and cosmetics for sterile powders like cephalosporins or lyophilized biologics.

Production Speeds: Ranges from 30–200 vials per minute (VPM) in compact GMP models to 300+ VPM in automated lines.

Advantages: High precision reduces waste, minimizes human intervention for sterility, and supports scalability. Compact designs fit under containment systems, and servo technology ensures repeatability.

Key Components of Vial Powder Filling Machine

Powder Dosing System: Utilizes vacuum-driven powder wheels or servo-controlled pistons for volumetric filling. Powder is stored in a hopper agitated by mechanical stirrers to maintain uniform density. Dosing ranges from 50mg to 1500mg per vial, with options for multiple doses via changeable parts.

Filling Accuracy: Typically ±2% (or better, up to ±0.05% in advanced servo models), depending on powder characteristics, humidity, and environmental conditions.

Stoppering Mechanism: Built-in rubber bunging or stoppering system inserts sterile stoppers immediately after filling to preserve integrity.

Turntables and Conveyor: Infeed and outfeed turntables with independent drives for smooth vial handling and speed control. Vials are transported via a synchronized conveyor or indexing system.

Safety and Controls: Includes clutch systems for vial breakage prevention, tool-less blade adjustments, PLC interfaces with graphical user interfaces (GUI), and optional in-process weight checking or rejection systems. Many models support IQ/OQ validation documentation.

Sterility Enhancements: Options for inbuilt laminar airflow (Class 100), autoclavable SS316 contact parts, and integration under isolators or RABS (Restricted Access Barrier Systems).

Customization: Servo motors for powder wheel rotation and vial transport; adaptable for different vial sizes . Advanced models allow split-filling of multiple powders in one vial with 100% check-weighing.

FAQ for Vial Powder 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 Powder Filling Machine

Description

Salient Features of Vial Powder Filling Machine

Working Principle of Vial Powder Filling Machine

Technical Specification of Vial Powder Filling Machine

Types of Vial Filling Machine

Applications of Vial Filling Machine

Benefits of Vial Powder Filling Machine

Industries: Primarily pharmaceuticals, biotech, and cosmetics for sterile powders like cephalosporins or lyophilized biologics.

Production Speeds: Ranges from 30–200 vials per minute (VPM) in compact GMP models to 300+ VPM in automated lines.

Advantages: High precision reduces waste, minimizes human intervention for sterility, and supports scalability. Compact designs fit under containment systems, and servo technology ensures repeatability.

Key Components of Vial Powder Filling Machine

FAQ for Vial Powder Filling Machine

Countries We Export to

Partner with Industry Experts

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