Vial Filling and Rubber Stoppering Machine

Q: What key features ensure sterility and reduce wastage?

Important features include: “ No Vial – No Filling ” and “ No Vial – Machine Stop ” systems SS 316L product contact parts Laminar airflow compatibility Acrylic safety enclosure Nitrogen flushing option (pre & post filling) PRIME function for fast cleaning and filling line priming These features maintain sterility and minimize product loss.

Description

In the fast-paced pharmaceutical manufacturing industry, the Vial Filling and Rubber Stoppering Machine stands as a critical piece of equipment for ensuring accurate, sterile, and efficient production of injectable liquids. Designed with advanced engineering and strict compliance to Good Manufacturing Practices (GMP), these automatic vial filling machines deliver exceptional performance while maintaining the highest standards of product safety and quality. As experienced manufacturers with deep expertise in pharmaceutical filling technology, we understand the stringent requirements of injectable production and deliver solutions that professionals trust.

The main structure of a high-quality vial filling and rubber stoppering machine is built for durability and contamination control. It features a protective safety acrylic cover supported by a stainless steel frame, creating a sterile environment. Integrated laminar air flow systems maintain ISO-class cleanroom conditions throughout the operation. The machine includes an in-feed turntable, a reliable peristaltic pump filling system, a smooth Delrin slat conveyor, an outfeed turntable, a vibrator bowl with rubber stopper chute, precision pneumatic components, and a modern electrical panel equipped with AC drive, PLC, and user-friendly HMI interface. Sterilized dry vials are automatically fed through an unscrambler and precisely positioned on the moving Delrin slat conveyor belt. The conveyor speed is adjustable to ensure perfect synchronization with the filling station, minimizing any risk of misalignment or breakage.

An automatic vial filling machine is an efficient and highly accurate device specifically engineered for filling glass vials with liquid injectables. After precise liquid dosing, the machine seamlessly inserts rubber stoppers to seal the vials, protecting the product from external contaminants. Both peristaltic pumps and piston pumps are utilized depending on the application, offering the highest level of filling accuracy. For standard round vials, automatic models are the preferred choice due to their speed, consistency, and ability to handle high-throughput requirements. The system ensures rubber stoppers are correctly positioned on top of each container, creating a secure, tamper-evident seal that meets regulatory standards.

As one of the leading vial filling machine manufacturers, we prioritize precision engineering that results in minimal waste, zero spillage, and maximum uptime. Our machines are designed to prevent contamination at every stage — from vial feeding to final stoppering — ensuring product integrity and patient safety.

One of the standout features of modern vial liquid filling machines is their outstanding accuracy and productivity. These machines typically achieve filling precision of ±1%, even when handling rubber stoppers with a 20 mm diameter. The output rate depends on factors such as the type of liquid, fill volume, and machine configuration.

For example:

An eight-head vial filling machine can deliver up to 150 fills per minute.
A four-head model achieves around 80 fills per minute.
A two-head vial filler produces 40 fills per minute.

The versatile vial filler supports a wide fill range from 2 ml to 250 ml in a single machine with single dosing capability. It requires only a 2 H.P. electric supply, making it energy-efficient while maintaining powerful performance. This flexibility allows pharmaceutical companies to use the same equipment for different batch sizes and formulations, reducing operational costs and changeover time.

Key advantages include:

High workability and reliable high-speed operation
Advanced PLC and HMI controls for easy operation and monitoring
Stainless steel construction for easy cleaning and sterilization
Minimal maintenance requirements
Compliance with international pharmaceutical standards

Whether you operate a small-scale facility or a large pharmaceutical plant, our vial filling and rubber stoppering machines provide scalable solutions that grow with your production needs. The combination of robust design, cutting-edge filling technology, and operator-friendly features makes these machines a smart investment for consistent, high-quality output.

With years of hands-on experience in designing and supplying vial liquid filling equipment, we deliver machines that pharmaceutical manufacturers worldwide rely on for their most critical production lines. Our commitment to excellence, continuous innovation, and customer support ensures you receive not just equipment, but a complete, trustworthy solution for your injectable filling requirements. Ready to enhance your production efficiency with state-of-the-art vial filling technology? Contact our team today to explore customized automatic vial filling and rubber stoppering machines tailored to your specific needs.

Salient Features of Vial Filling and Stoppering Machine

No cross contamination.
Suitable for the filling Volume of 2ml to 250ml.
Piston pump/Peristaltic pump aseptic filling.
Filling with accuracy of ±0.5-1%.
Easy to validate filling system for small/large batch production.
All Contact Parts Made from S.S 316L & framework by S.S. 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 to comply vial filling machine validation process.
PLC with Graphical User Interface. (Optional)
PRIME is a distinctive feature that allows you to quickly suck filling material from the storage tank to the nozzle end. This feature is also beneficial for cleaning the filling line (silicon tubing) and filling the peristaltic pump in both directions.
PLC alarms for “No Vial, Machine Stop” and “No Vial, No Bung.”
For daily track reports and planning, a password-protected production counter is provided.
The errors can be recognized on the touch screen HMI of the PLC and readily attended to.

The machine can use the PRIME function for all peristaltic pumps together or for individual peristaltic pump.
Filling is done with a specifically built filling peristaltic pump which has CIP and SIP ability.
Individual pumps may be calibrated and adjusted for the desired volume using a simple PLC.
Because of a particularly built peristaltic pump with suck back capability, oil-based materials can also be run without dripping.
Each filling head may operate independently, allowing the machine to operate constantly without sacrificing significant production.
Bung orientation bowl and discharge chute with built-in vibrator. For use with wet bungs, we offer bung orienter bowl and chute with Teflon coating.
Bungs are held in a specifically designed vacuum bung hold disc, which then discharges the bung evenly onto the vial. The bung pressing roller evenly presses the bungs.
Half stoppering can be done with the same Rubber bunging machine assembly.
Each filling head may operate independently, allowing the machine to operate constantly without sacrificing significant production.
For varied sizes of vials and filling volumes, no change parts are necessary.
Because mechanical parts like syringe sets, Teflon seals, gears, and chains are rarely used, there is relatively little product variation over time.
PLC with simple controls for volume and speed adjustments.
The entire assembly can be adjusted upwards and lower to accommodate different heights of vials.
To avoid the negative effects of the electric supply, the machine is supplied with an isolated power source.
Well known mechanical components such as FESTO/Janatics pneumatics and CE approved electrical/electronic components such as Bonfiglioli/Crompton AC motors, Allen Bradley drives, PLC & HMI Touch screen, Sensors, MCB’s, relays, and other components.

Working Principle of Vial Filling and Rubber Stoppering Machine

The incoming dry vials (sterilized and siliconised) are fed through the in-feed turn table and suitably guided on the moving Stainless Steel slat conveyor belt at the required speed of the correct placement below filling unit.

The filling unit consists syringes & nozzles. Syringes are made of Stainless Steel 316L material for cGMP compliance. Vials stop below filling unit with centering of filling nozzles, during stoppage nozzles discharge pre determined liquid into vials. Duly filled vials delivered on stoppering unit which is mounted on same platform.

Stoppering Unit consist Bowl and Chute designed for desired stopper / bung size. Stoppers are stored in vibratory bowl and delivered to the vial through delivery chute. Vibratory bowl is equipped with special vibrator motor. Stoppers travel in vibratory bowl support guide through vibration. There is arrangement in the bowl in which wrong position stopper get rejected in travelling and only correct position of stopper get into chute. Further stoppers hold at delivery point of chute through spring which collected one by one by vial in traveling below the chute. Further there is one Stainless Steel 304 roller installed to press the stoppers. Vial transfer below the wheel in which get stoppered.

Duly stoppered vials further move on conveyor & collected on out feed turn table (optional) or on to conveyor of vial aluminum cap sealing machine for cap sealing operations.

Vial Loading: Empty, sterilized vials are fed via the infeed turntable onto a conveyor.

Filling Process: Vials move to the filling station, where nozzles descend to inject the exact volume of liquid. The synchronized motion filling system allows nozzles to track vials without stopping the line, enhancing speed.

Stoppering Process: Filled vials transfer to the stoppering station, where a vibrating bowl dispenses oriented rubber stoppers into a chute. Vials are held by a rotating star wheel, picking up stoppers that are then pressed down by rollers.

Output: Stoppered vials exit via the outfeed turntable for further processes like capping or labeling.

Technical Specification of Vial Filling and Rubber Stoppering 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

Benefits of Vial Filling and Stoppering Machine

High Production Efficiency and Speed

Superior Filling Accuracy and Reduced Product Waste

Enhanced Sterility and Product Safety

Easy Operation, Quick Changeover, and Low Maintenance

Labor Savings, Cost Efficiency, and Seamless Line Integration

Key Components and Features of Vial Filling and Stoppering Machine

Infeed and Outfeed Systems: Built-in turntables with individual drives for smooth vial entry and exit, often including a Delrin slat conveyor to prevent sticking and ensure consistent movement.

Filling Station: Equipped with multiple heads (e.g., 2, 4, 8, or 12) for simultaneous filling. Nozzles move vertically via cam mechanisms for precise dosing, with options for nitrogen flushing before and after filling to minimize oxidation. A “No Vial, No Fill” system prevents liquid wastage.

Stoppering Unit: Features a vibrating bowl and Teflon-coated chute for orienting and feeding rubber stoppers. Vacuumetric or pneumatic systems pick and press stoppers uniformly using spring-loaded rollers, supporting both full and half-stoppering.

Safety and Construction: All liquid-contact parts are made of stainless steel (SS 316L) for easy sterilization and autoclaving. The machine includes acrylic safety covers, laminar airflow for cleanroom compatibility, and PLC/HMI controls for automation.

Drive System: Powered by high-quality gear motors and AC drives for vibration-free operation, with minimal oil leakage.

FAQ for Automatic Vial Filling and Stoppering Machine

What is a Vial Filling and Rubber Stoppering Machine?

A Vial Filling and Rubber Stoppering Machine is a compact monoblock automatic system designed for aseptic filling of sterile liquid injectables into glass vials followed by precise rubber stopper (bung) insertion. It integrates filling and stoppering on a single platform under laminar airflow to minimize contamination risk. It is widely used in pharmaceutical and biotech industries for vaccines, antibiotics, and other parenteral products.

What is the filling accuracy of the machine?

The machine delivers high filling accuracy of ±0.5% to ±1%. It uses advanced peristaltic pumps or piston pumps with SS 316L syringes and nozzles. Features like suck-back system (anti-dripping) and independent head operation ensure consistent dosing with minimal product wastage.

How does the rubber stoppering system work?

Sterilized rubber stoppers are loaded into a vibratory bowl. The oriented stoppers travel through a Teflon-coated chute and are placed onto the filled vials. A vacuum or mechanical hold disc and pressing roller ensure accurate and uniform stoppering. The system also rejects wrongly oriented stoppers automatically.

What key features ensure sterility and reduce wastage?

Important features include:

“No Vial – No Filling” and “No Vial – Machine Stop” systems
SS 316L product contact parts
Laminar airflow compatibility
Acrylic safety enclosure
Nitrogen flushing option (pre & post filling)
PRIME function for fast cleaning and filling line priming

These features maintain sterility and minimize product loss.

Is the machine cGMP compliant and customizable?

Yes. The machine is fully cGMP compliant and meets USFDA, EU-GMP, and WHO standards. All contact parts are SS 316L and framework is SS 304. It can be customized with PLC + HMI, CIP/SIP capability, inbuilt laminar airflow, and IQ/OQ documentation. Minimal change parts are required for different vial sizes.

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Vial Filling and Rubber Stoppering Machine

Description

Salient Features of Vial Filling and Stoppering Machine

Working Principle of Vial Filling and Rubber Stoppering Machine

Technical Specification of Vial Filling and Rubber Stoppering Machine

Types of Vial Filling Machine

Applications of Vial Filling Machine

Benefits of Vial Filling and Stoppering Machine

High Production Efficiency and Speed

Superior Filling Accuracy and Reduced Product Waste

Enhanced Sterility and Product Safety

Easy Operation, Quick Changeover, and Low Maintenance

Labor Savings, Cost Efficiency, and Seamless Line Integration

Key Components and Features of Vial Filling and Stoppering Machine

FAQ for Automatic Vial Filling and Stoppering Machine

Countries We Export to

Partner with Industry Experts

Countries We Export to

Partner with Industry Experts

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