Injection Vial Filling Machine

Q: How does the machine ensure filling accuracy?

Modern machines utilize high-precision volumetric piston pumps or peristaltic pumps controlled by servo motors. These systems allow for fine-tuned adjustments, often achieving an accuracy of ±0.5% to ±1%. Many high-end models also feature a 'No Vial, No Fill' sensor system to prevent wastage and maintain a clean conveyor environment.

Q: Does the machine include bunging (stoppering) and capping?

While standalone fillers exist, most 'Injection Vial Filling Machines' are sold as Monoblock systems . This means the filling, rubber stoppering (bunging), and sometimes the aluminum cap sealing are all performed on a single synchronized base. This reduces the footprint and minimizes the risk of contamination between the filling and sealing stages.

Description

Specialised equipment called Injection Vial Filling Machine is used to precisely fill vials with liquid drugs. S.S. slat conveyor belts, eccentric pre-gassing, filling, and post-gassing S.S. 316 nozzles, precision-built S.S. 316 syringes, silicon rubber tubings, easy-to-reach small panels, and other components make up the machine. The risk of contamination is decreased because there is less space between filling and stoppering. It is intended to be used under laminar flow protection and to function in a sterile environment. The machine’s un-scrambler was built to remove dead ends and hard-to-clean areas. In the pharmaceutical sector, liquid filling procedures must be precise and effective. The key elements in simplifying these processes and guaranteeing that each vial is filled precisely and quickly are injectable liquid filling devices. Large volumes of vials can be handled with remarkable efficiency by high-speed vial filling machines. Additionally, these devices are designed to optimise throughput while upholding strict quality control. The high-speed vial filling’s cutting-edge technology guarantees that the manufacturing lines can run at maximum efficiency, cutting downtime and increasing output.

With 8000 machine installations worldwide, Adinath International is a significant manufacturer of injectable vial filling machines in India. We have a variety of vial filling machines, with tiny vial filling machines being the preferred option for small-scale manufacturing, research facilities, and R&D labs. For medium-sized and large-scale pharmaceutical production companies, high-speed vial filling machines are an appropriate option. Adinath is a well-known manufacturer of vial filling machines in India because of its robust mechanism, low maintenance requirements, and user-friendliness.

Vial Preparation: Sterilized vials (pre-washed with Water for Injection and depyrogenated via tunnels) are fed via an in-feed turntable and conveyor.

Filling: Vials are positioned under filling nozzles; liquid or powder is dispensed accurately based on volume sensors. Nitrogen gassing may occur before/after to prevent oxidation.

Stoppering: Rubber stoppers are partially inserted using vacuum or mechanical systems to seal the vial while allowing for final capping.

Capping and Sealing: Aluminum caps are applied and crimped for tamper-evident security.

Output: Filled vials exit via out-feed conveyor for downstream processes like inspection, labeling, or packaging. The entire process is monitored for sterility and rejects defective units.

Salient Features of Injection Vial Filling Machine

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 Injection Vial 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 Injection Vial 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
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

Advantages of Injection Vial Filling Machine

Exceptional Precision and Accuracy

Guaranteed Sterility and Hygiene

High Production Speed and Efficiency

Versatility and Adaptability

Enhanced Safety and Compliance

Key Feature of Injection Vial Filling Machine

Construction: Typically made from stainless steel to prevent corrosion and ensure easy cleaning/validation. Includes in-feed turntables, slat conveyors, and out-feed systems for smooth vial handling.

Filling Mechanism: Uses peristaltic, volumetric, or servo-driven pumps for ±1% filling accuracy. Supports pre- and post-gassing to displace oxygen and maintain sterility.

Stoppering and Capping: Integrates rubber bunging (stoppering) and aluminum cap sealing in a monobloc design, reducing contamination exposure.

Safety Features: “No vial, no fill” sensors, digital counters, and variable AC frequency drives for speed control. Often equipped with inbuilt laminar airflow for Class 100 sterile environments.

Versatility: Handles vial sizes from 2ml to 250ml, various liquid viscosities, and powder formulations. Options for multiple filling heads and integration with washing, drying, inspection, and labeling stations.

FAQ for Injection Vial Filling Machine

What is the production capacity of an Injection Vial Filling Machine?

Production capacity varies significantly based on the number of filling heads and the vial size. Entry-level machines typically start at 20 to 40 vials per minute, while high-speed industrial lines with 8 to 12 heads can exceed 300 to 400 vials per minute. The viscosity of the liquid and the neck diameter of the vial also influence the final output speed.

How does the machine ensure filling accuracy?

Modern machines utilize high-precision volumetric piston pumps or peristaltic pumps controlled by servo motors. These systems allow for fine-tuned adjustments, often achieving an accuracy of ±0.5% to ±1%. Many high-end models also feature a “No Vial, No Fill” sensor system to prevent wastage and maintain a clean conveyor environment.

Can one machine handle different vial sizes and fill volumes?

Yes. Most injection vial filling machines are designed with interchangeable change parts. By swapping out the star wheels, guide rails, and syringes, you can process various vial diameters (e.g., 2ml to 100ml). Transitioning between fill volumes is usually managed via the PLC touchscreen interface without needing to dismantle the entire pump assembly.

What are the sterilization and cleaning standards for these machines?

To meet strict pharmaceutical cGMP (current Good Manufacturing Practice) standards, the contact parts are typically made of Stainless Steel 316L. The machines are designed for:

CIP (Clean-in-Place): Automated cleaning of internal fluid paths.
SIP (Sterilization-in-Place): Using steam to sterilize the system without disassembly.
Laminar Air Flow (LAF) Compatibility: Ensuring the filling zone remains a Grade A sterile environment.

Does the machine include bunging (stoppering) and capping?

While standalone fillers exist, most “Injection Vial Filling Machines” are sold as Monoblock systems. This means the filling, rubber stoppering (bunging), and sometimes the aluminum cap sealing are all performed on a single synchronized base. This reduces the footprint and minimizes the risk of contamination between the filling and sealing stages.

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