Pharmaceutical Vial Filling Machine

Q: How does the machine ensure sterile conditions during the filling process?

Sterility is maintained through a combination of Laminar Air Flow (LAF) systems , cGMP-compliant stainless steel (SS 316L) contact parts, and compatibility with Isolator or RABS (Restricted Access Barrier Systems) technology. These features prevent environmental contamination and ensure the product remains pyrogen-free.

Q: How is filling accuracy maintained to prevent product waste?

Accuracy is typically managed via Servo-driven filling systems or Mass Flow Meters . These technologies allow for precise control over the stroke of the pump, often achieving an accuracy of ±0.5% to ±1% of the fill volume. Many high-end models also feature 'In-Process Check weighing' (IPC) to adjust volumes in real-time.

Q: Can the machine handle different vial sizes and stopper types?

Yes. Most machines are built with tool-less changeover parts , allowing them to adapt to various vial diameters (2ml to 100ml) and heights. Similarly, the stoppering unit can be adjusted for different rubber stopper styles, including those for lyophilization (freeze-drying) which are only partially inserted.

Description

Pharmaceutical Vial filling machine from Adinath International are a component of end-to-end, smoothly integrated lines that adjust to shifting batch sizes, confinement approaches, and vial formats. A Vial Filling Machine is a technically sophisticated device that accurately fills and dispenses liquid or powder materials. These are prefabricated little bottles that are often made of special polymers or borosilicate glass. The open handling of the containers between cleaning and sealing is a crucial step in this process, which is why the strictest environmental hygiene regulations are applicable.

The pharmaceutical sector makes considerable use of vial filling machines to fill vials with pharmaceutical substances. These incredibly robust devices are made to carry out the exact process of quickly filling vials. In order to satisfy the expectations of the pharmaceutical business, vial filling machines also have several filling heads, which allow them achieve a higher filling rate and increased productivity. Vial-filling machines come in a variety of forms that are appropriate for various uses in the pharmaceutical sector. With integrated isolator, freeze-drying, and inspection solutions, our equipment facilitates quick format changes, multi product processing, and easier (re-)validation. With over 8000 installations across the globe, we assist you in increasing capacity while maintaining flexibility, effectiveness, and regulatory readiness.

Common Configurations

Monoblock: Compact design combining filling, stoppering, and capping in one unit

Linear Filling Lines: Ideal for small to medium batches with easy changeover

Rotary Filling Lines: High-speed continuous motion for large-scale production

Robotic Filling Systems: Fully flexible, tool-less changeover for small-batch/multiproduct facilities

Salient Features of Pharmaceutical 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 Pharmaceutical 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 Pharmaceutical 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 Vial Filling Machine

Unmatched Precision and Accuracy

High Production Speed

Enhanced Sterility and Safety

Integration and Versatility

Regulatory Compliance

Key Features & Functions of Pharmaceutical Vial Filling Machine

Filling Technologies: Peristaltic pumps, piston pumps, time-pressure, or mass flow filling for high accuracy

Stoppering & Capping: Integrated in-line or rotary systems for partial or full rubber stopper insertion and aluminum crimp capping

Sterility Options:
- Aseptic filling with isolators/RABS
- Laminar airflow (LAF) or oRABS
- Vaporized Hydrogen Peroxide (VHP) decontamination

Vial Handling: No-glass-to-glass contact, starwheels, puck systems, or robotic handling to prevent breakage and contamination

Capacity Range: From laboratory-scale to high-speed production lines

Vial Sizes: Typically 2 ml to 100 ml

Cleaning & Sterilization: CIP/SIP capable

FAQ for Pharmaceutical Vial Filling Machine

What types of liquids can a pharmaceutical vial filling machine handle?

These machines are designed for versatility and can process a wide range of viscosities. This includes aqueous solutions, oils, suspensions, and high-viscosity gels. Most modern units utilize peristaltic or piston pumps to ensure that even shear-sensitive biological products are filled without degradation.

How does the machine ensure sterile conditions during the filling process?

Sterility is maintained through a combination of Laminar Air Flow (LAF) systems, cGMP-compliant stainless steel (SS 316L) contact parts, and compatibility with Isolator or RABS (Restricted Access Barrier Systems) technology. These features prevent environmental contamination and ensure the product remains pyrogen-free.

What is the typical production speed (output) of these machines?

Output varies significantly based on the number of filling heads.

Lab-scale/Manual: 10–30 vials per minute.
Automatic Linear Machines: 60–120 vials per minute.
High-speed Rotary Machines: 250+ vials per minute. The speed is also influenced by the fill volume and the foaming characteristics of the liquid.

How is filling accuracy maintained to prevent product waste?

Accuracy is typically managed via Servo-driven filling systems or Mass Flow Meters. These technologies allow for precise control over the stroke of the pump, often achieving an accuracy of ±0.5% to ±1% of the fill volume. Many high-end models also feature “In-Process Check weighing” (IPC) to adjust volumes in real-time.

Can the machine handle different vial sizes and stopper types?

Yes. Most machines are built with tool-less changeover parts, allowing them to adapt to various vial diameters (2ml to 100ml) and heights. Similarly, the stoppering unit can be adjusted for different rubber stopper styles, including those for lyophilization (freeze-drying) which are only partially inserted.

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