Vial Liquid Filling Machine

Q: What is the production capacity of the Vial Liquid Filling Machine?

The machine is available in different models: ALVF-40 (2 Heads): Up to 40 vials/min ALVF-80 (4 Heads): Up to 80 vials/min ALVF-120 (8 Heads): Up to 150 vials/min ALVF-250 (12 Heads): Up to 250 vials/min Output depends on vial size, fill volume, and liquid viscosity. Speed is easily adjustable with a variable AC frequency drive.

Q: What vial sizes and fill volumes does it support?

The machine handles 2 ml to 250 ml fill volumes. Vial Diameter: 15 mm to 70 mm Vial Height: 25 mm to 140 mm It supports quick changeover with minimal change parts for different vial formats and is compatible with various rubber stoppers (full or half stoppering).

Q: What features make this machine suitable for sterile production?

Key features include: “No Vial – No Filling” system All product contact parts in SS 316L Compatibility with Class 100 laminar airflow Nitrogen flushing (pre & post filling) option Digital vial counter and variable speed control Easy-to-clean and autoclavable parts

Description

Vial Liquid Filling Machine, also commonly known as the Injection Vial Filling Machine, is a compact yet highly advanced monobloc system designed specifically for filling liquid injection vials used in pharmaceutical manufacturing. This versatile equipment integrates both filling and rubber stoppering (bunging) functions on a single platform, delivering exceptional efficiency and accuracy. As experienced manufacturers of pharmaceutical filling technology, we engineer these machines to meet the most stringent regulatory standards while ensuring reliable, contamination-free performance that pharmaceutical companies worldwide trust.

For full GMP compliance, all product-contact parts in our vial filling machines are constructed from high-grade stainless steel or other FDA-approved materials. This hygienic design minimizes contamination risks and facilitates easy cleaning and sterilization. The machine offers multiple filling pump options, including peristaltic and piston pumps, achieving consistent ±1% filling accuracy across a wide range of viscosities. We also provide complete integrated lines, combining the vial filling machine with our Vial Cap Sealing Machine and Vial Labeling Machine, creating a fully automated Vial Filling, Stoppering, Sealing, and Labeling Line for end-to-end processing.

The vial liquid filling machine performs multiple critical operations in one seamless process:

Filling: Precisely dispenses exact volumes of liquid product into each vial using advanced nozzles or needles.

Rubber Stoppering: Automatically inserts pharmaceutical-grade rubber stoppers to prevent contamination and leakage.

Cap Sealing: Applies secure closures (such as aluminum flip-off caps) to complete the sealing process.

This monobloc design significantly reduces footprint, handling time, and potential contamination points compared to separate machines.

Our automatic vial filling machines follow a carefully controlled sequence ideal for sterile production:

Vial Feeding: Empty, pre-sterilized vials are loaded and automatically aligned on the conveyor system.

Preparation: Vials move through washing and sterilization zones under laminar airflow in a Class 100 cleanroom environment.

Filling: Diving nozzles dispense liquid at controlled speeds. Optional nitrogen flushing displaces oxygen to enhance product stability and extend shelf life.

Closing: Rubber stoppers are inserted followed by cap application, often with 100% in-process verification for quality assurance.

Output: Filled, stoppered, and sealed vials are gently ejected for downstream processes such as inspection or packaging.

Our vial filler range delivers output speeds between 20 to 250 VPM (vials per minute), with high-speed models capable of reaching 100–600 vials per minute depending on configuration. These machines excel in high-volume production settings where accuracy, speed, and reliability are non-negotiable.

Key benefits include:

Superior filling precision with minimal wastage
Full integration of filling, stoppering, and sealing
Cleanroom-compatible design with laminar airflow protection
Robust, low-maintenance construction
Easy validation and compliance documentation

With proven expertise in pharmaceutical equipment manufacturing, we deliver vial liquid filling machines that combine cutting-edge technology with practical usability. Our systems help manufacturers achieve high-quality, sterile injectable products efficiently while maintaining full traceability and regulatory compliance. Whether you need a standalone monobloc filler or a complete automated production line, our Injection Vial Filling Machines provide the precision, efficiency, and trustworthiness essential for modern pharmaceutical manufacturing. Contact our team for tailored solutions designed around your specific production requirements.

Salient Features of Vial Liquid Filling Machine

Compact footprint cGMP complied models.
2ml to 250ml fill dosage compatibility.
Filling accuracy of ±1% depends upon fluid & vial types.
No cross contamination.
On-line Mechanism.
Variable A.C. frequency drive for speed adjustment.
Digital Vial Counter for counting production output.

All Contact Parts Made from AISI SS 316L & framework by AISI SS 304.
Easy to validate filling system for small/large batch production.
In-feed Turn Table/ Unscrambler attached with the machine for automatic feeding of vials.
“No Vial – No Filling” system feature.
IQ/OQ documentation can be provided.
PLC system with Graphical User Interface. (Optional)

Working Principle of Vial Liquid 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 Vial Liquid 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 Liquid Filling Machine

Benefits of Vial Liquid Filling Machine

Precision and Compliance: Ensures exact dosing (±0.05–0.5%) and sterility, reducing rejects via features like re-stoppering.

Efficiency: Boosts throughput while integrating with downstream processes like freeze-drying for extended shelf life.

Versatility: Handles various liquids (e.g., oncology drugs, vaccines) and formats in cleanrooms.

Safety: Includes safeguards like no-bottle sensors and HEPA filtration to protect operators and products.

Key Components of Vial Liquid Filling Machine

Vial liquid filling machines are modular and often integrated into complete production lines. Common components include:

Unscrambler and Conveyor: Orient and transport vials to the filling station via a belt or rotary system.

Washing and Sterilizing Stations: Clean vials internally and externally using deionized water, air drying, and depyrogenation with hot air or steam to remove endotoxins.

Filling Heads/Nozzles: Servo-controlled peristaltic, piston, or time-pressure pumps deliver precise volumes without contact to avoid contamination.

Stoppering and Capping Unit: Inserts rubber stoppers and applies aluminum seals or crimps for secure closure.

Inspection Systems: Inline sensors for weight checking, leak detection, particle inspection, and container integrity.

Control Systems: PLC-based with touchscreens for real-time monitoring, recipe storage, and integration with lyophilizers or labeling machines.

FAQ for Vial Liquid Filling Machine

What is a Vial Liquid Filling Machine?

A Vial Liquid Filling Machine is a monoblock automatic system designed for precise filling of sterile liquids into glass vials followed by rubber stoppering. It is widely used in the pharmaceutical industry for injectable products such as vaccines, antibiotics, biotech formulations, and other parenteral liquids. The machine performs filling and stoppering on a single platform under aseptic conditions to minimize contamination.

What is the production capacity of the Vial Liquid Filling Machine?

The machine is available in different models:

ALVF-40 (2 Heads): Up to 40 vials/min
ALVF-80 (4 Heads): Up to 80 vials/min
ALVF-120 (8 Heads): Up to 150 vials/min
ALVF-250 (12 Heads): Up to 250 vials/min

Output depends on vial size, fill volume, and liquid viscosity. Speed is easily adjustable with a variable AC frequency drive.

What vial sizes and fill volumes does it support?

The machine handles 2 ml to 250 ml fill volumes.

Vial Diameter: 15 mm to 70 mm
Vial Height: 25 mm to 140 mm

It supports quick changeover with minimal change parts for different vial formats and is compatible with various rubber stoppers (full or half stoppering).

What is the filling accuracy and technology used?

The Vial Liquid Filling Machine offers a filling accuracy of ±1% (or better depending on liquid characteristics). It uses high-precision SS 316L syringes, piston pumps with non-return valves, and a diving nozzle system with cam-operated movement to ensure accurate, drip-free, and foam-free filling.

What features make this machine suitable for sterile production?

Key features include:

“No Vial – No Filling” system
All product contact parts in SS 316L
Compatibility with Class 100 laminar airflow
Nitrogen flushing (pre & post filling) option
Digital vial counter and variable speed control
Easy-to-clean and autoclavable parts

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Connect with our engineering team to discuss your specific production requirements. We provide customized, cGMP-compliant machinery solutions designed to optimize your manufacturing facility and maximize output.

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Vial Liquid Filling Machine

Description

Salient Features of Vial Liquid Filling Machine

Working Principle of Vial Liquid Filling Machine

Technical Specification of Vial Liquid Filling Machine

Types of Vial Filling Machine

Applications of Vial Liquid Filling Machine

Benefits of Vial Liquid Filling Machine

Precision and Compliance: Ensures exact dosing (±0.05–0.5%) and sterility, reducing rejects via features like re-stoppering.

Efficiency: Boosts throughput while integrating with downstream processes like freeze-drying for extended shelf life.

Versatility: Handles various liquids (e.g., oncology drugs, vaccines) and formats in cleanrooms.

Safety: Includes safeguards like no-bottle sensors and HEPA filtration to protect operators and products.

Key Components of Vial Liquid Filling Machine

FAQ for Vial Liquid Filling Machine

Countries We Export to

Partner with Industry Experts

Countries We Export to

Partner with Industry Experts

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