Automatic Vial Filler

Description

A specialised piece of equipment used in the pharmaceutical business to fill vials containing liquid or powder products is called a Automatic Vial Filler. This kind of equipment is a very effective and efficient instrument for pharmaceutical manufacture since it can do multiple tasks at once. Precise volumes of liquid or powder substance are dispensed into each vial via the machine’s vial filling component. The cap sealing component applies a closure to the vial to finish the sealing operation, while the rubber stoppering component places a rubber stopper inside the vial to stop contamination or leaks.

These devices are usually employed in high-volume manufacturing environments where dependability, speed, and accuracy are essential for effective output. Additionally, they are frequently employed in cleanroom settings to guarantee that goods are manufactured in a sterile and regulated setting. All things considered, vial filling, rubber stoppering, and cap sealing machines are crucial equipment for pharmaceutical production, allowing producers to quickly, accurately, and efficiently create high-quality goods.

The main structure of the Automatic Vial Filling and Rubber Stoppering Machine is protected by a safety acrylic cover made of stainless steel, laminar air flow, an in-feed turntable, a peristaltic pump filling machine, a Delrin Slate conveyor, an outfeed turn table, a vibrator bowl and rubber stopper chute, pneumatic parts, an electrical panel, an AC drive, a PLC, and an HMI.

Salient Features of Automatic Vial Filler

Suitable for the filling Volume of 2ml to 250ml.
Piston pump/Peristaltic pump aseptic filling.
Filling accuracy of ±0.5% to ±1%.
No cross contamination.
Easy to validate filling system for small/large batch production.
All Contact Parts Made from Stainless Steel 316L & framework by Stainless Steel 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.
PLC system with Graphical User Interface. (Optional)

Working Principle of Automatic Vial Filler

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 Automatic Vial Filler

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 Automatic Vial Filler

Advantages of Automatic Vial Filler

High accuracy (±0.5% fill volume)

Reduced contamination risk

Scalable for small batch to high-volume production

Full traceability and data logging

Key Features of Automatic Vial Filler

Filling Mechanisms:
- Peristaltic pumps – Ideal for sterile, low-viscosity liquids; easy to clean.
- Piston pumps – Suitable for viscous liquids or suspensions.
- Time-pressure filling – Used for high-precision, foam-sensitive products.
- Mass flow filling – For high-accuracy filling based on weight.

Vial Handling:
- Automatic infeed systems (e.g., rotary tables, conveyor belts).
- Denesting and positioning of vials.
- Supports various vial sizes (2mL to 100mL typically).

Sterility & Cleanliness:
- Laminar airflow hoods (LAF) or isolators.
- Clean-in-place (CIP) and sterilize-in-place (SIP) capabilities.
- HEPA filtration.

Capping & Sealing:
- Integrated crimping or screw-capping stations.
- Stopper placement (rubber stoppers for injectables).

Controls & Monitoring:
- PLC (Programmable Logic Controller) with HMI touchscreen.
- Fill volume verification via check-weigh systems or vision inspection.
- Rejection of under/over-filled or defective vials.

FAQ for Automatic Vial Filler

What is an Automatic Vial Filler?

An Automatic Vial Filler is a fully automated pharmaceutical machine designed to precisely dispense liquids, suspensions, or other injectable formulations into glass or plastic vials. It typically integrates vial feeding, filling, stoppering, and in some models, capping in a single continuous process. These machines are widely used in sterile manufacturing environments to ensure high-speed, accurate, and contamination-free filling while complying with cGMP, EU-GMP, and FDA standards.

What are the main advantages of using an Automatic Vial Filler?

Automatic vial fillers offer significantly higher production speeds (up to thousands of vials per hour), superior filling accuracy (often ±0.5% or better), reduced labor costs, and minimized human intervention. They provide excellent consistency, lower product waste, better contamination control in aseptic conditions, and easier regulatory compliance. Compared to manual or semi-automatic systems, they improve overall efficiency and product safety, especially for high-value injectables and biologics.

What types of products can an Automatic Vial Filler handle?

Our Automatic Vial Filler is suitable for a wide range of pharmaceutical liquids, including aqueous solutions, viscous suspensions, vaccines, antibiotics, and other sterile injectables. It can handle different vial sizes (commonly 2ml to 100ml or more) with quick changeover options. For powder filling or special formulations, customized versions or integrated lines are also available.

What is the typical filling speed and accuracy of an Automatic Vial Filler?

Filling speeds usually range from 1,000 to 12,000+ vials per hour, depending on the number of filling heads (e.g., 2, 4, 6, 8, or 12 heads) and vial size. Accuracy is typically within ±0.5% to ±1%, thanks to advanced peristaltic pumps, servo-driven volumetric systems, or time-pressure filling technology. Many models include “No Vial – No Fill” sensors and in-line check-weighing for 100% quality control.

How does an Automatic Vial Filler ensure sterility and regulatory compliance?

The machine is designed for use in ISO 5 / Grade A aseptic environments with features like closed filling systems, HEPA-filtered laminar airflow, CIP/SIP (Clean-in-Place/Sterilize-in-Place) capability, and minimal product contact parts made from FDA-approved materials (e.g., 316L stainless steel). It supports full process validation, data logging, and 21 CFR Part 11 compliant controls, making it easier to meet stringent pharmaceutical regulatory requirements.

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