Automatic Vial Filling and Plugging Machine

Q: What vial sizes can the Automatic Vial Filling and Plugging Machine handle, and how easy is changeover?

The machine supports a wide range of vial sizes: Filling Volume : 2ml to 250ml Vial Diameter : 15mm to 70mm Vial Height : 25mm to 140mm It is suitable for both small and large batch production. Changeover between different vial sizes and fill volumes is quick and easy using minimum change parts. Volume adjustment is done simply by increasing or decreasing the piston stroke length, with variable AC frequency drive for speed control.

Q: What are the power requirements and key safety features of the Automatic Vial Filling and Plugging Machine?

Power requirements are model-specific: ALVF-40 : 1 HP ALVF-80 : 1.5 HP ALVF-120 & ALVF-250 : 2 HP (All models operate on 440 Volts, 3 Phase, 50 Hz – customizable as per customer requirements.) Key safety and operational features include: “No Vial – No Filling” and “No Vial – Machine Stop” systems with sensors. Safety enclosures (acrylic covers). Digital vial counter. In-feed and out-feed turntables with stainless steel or Delrin slats. Easy accessibility for cleaning and low maintenance. The machine integrates seamlessly with vial washing, sterilization, capping, and labeling equipment for a complete production line.

Description

Automatic Vial Filling and Plugging Machine (also known as a Vial Filling and Stoppering Machine or Vial Filling and Rubber Stoppering Machine) is a specialized pharmaceutical packaging equipment designed for the precise, sterile filling of liquid formulations (such as injectables, vaccines, or other parenteral products) into glass or plastic vials, followed by automatic insertion of rubber stoppers (plugs or bungs).

It is widely used in the pharmaceutical, biotech, and sterile manufacturing industries to ensure high accuracy, minimize contamination risk, and comply with cGMP (current Good Manufacturing Practices) standards. These machines often integrate with upstream processes (vial washing and sterilization) and downstream ones (capping/sealing and labeling) in fully automatic production lines. It is obvious that the Automatic Filling Plugging Machine requires a sanitary working environment. Additionally, it provides protection against laminar flow. In order to eliminate dead ends and thoroughly clean the machine, the un-scramble has been redesigned.

Salient Features of Vial Filling and Plugging Machine

Compact cGMP model.
Suitable for the filling Volume of 2ml to 250ml.
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 Filling and Plugging 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.

Vial Feeding — Sterilized and siliconized vials are loaded onto an in-feed turntable or conveyor belt.

Positioning — Vials move on a stainless steel slat conveyor and are precisely centered under the filling nozzles.

Filling — Pre-determined volumes of liquid are dispensed via syringes/nozzles (volumetric or peristaltic pumps). Nozzles often dive into the vial to minimize splashing or foaming.

Stoppering/Plugging — Filled vials advance to the stoppering station, where rubber bungs are automatically fed from a bowl and inserted (often with vacuum or pneumatic assistance).

Ejection — Stoppered vials are transferred to an out-feed turntable or conveyor for further processing (e.g., capping, inspection, or packaging).

The entire process occurs in a controlled sterile environment, often under laminar airflow, to ensure product integrity.

Technical Specification of Automatic Vial Filling and Plugging 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 Automatic Vial Filling and Plugging Machine

High speed and accuracy reduce product loss and labor costs.

Ensures sterility and minimizes contamination risk.

Easy changeover with quick-adjust parts.

Integrated safety features and low maintenance.

Key Features of Automatic Vial Filling and Plugging Machine

Compact and cGMP-compliant design: Typically features stainless steel (SS 316L) contact parts, laminar airflow protection, and safety enclosures (e.g., acrylic covers) to maintain sterility.

Filling accuracy: Usually ±0.5% to ±1%, achieved through volumetric piston pumps, peristaltic pumps, or servo-controlled systems.

No Vial – No Fill system: Prevents wastage and contamination by detecting the presence of vials before filling.

Versatile vial handling: Suitable for vial sizes ranging from 2 ml to 250 ml (diameters 15–70 mm, heights 25–140 mm, depending on the model).

Multi-head configurations: 2, 4, 8, or more filling heads for higher throughput.

Plugging/stoppering unit: Includes a vibrator bowl and chute for automatic feeding and precise placement of rubber stoppers (common sizes: 13 mm, 20 mm, 32 mm).

Automation level: Fully automatic with PLC, HMI (touchscreen), and AC drives for easy operation and monitoring. Some models support semi-automatic modes.

Additional options: Diving nozzles to reduce foaming, in-feed/out-feed turntables, conveyor belts (stainless steel or Delrin slats), and integration with capping/sealing stations.

FAQ for Automatic Vial Filling and Plugging Machine

What is an Automatic Vial Filling and Plugging Machine and what does it do?

The Automatic Vial Filling and Plugging Machine is a fully automatic monoblock system designed to fill sterile liquid formulations (such as injectables, vaccines, and serums) into glass vials and insert rubber stoppers in a single continuous operation. It features diving nozzles to minimize foaming and splashing, a stoppering unit with a vibrator bowl and spring-loaded pressing roller, and precise volumetric filling. Built as a compact cGMP model, it ensures high accuracy, sterility, and no cross-contamination for pharmaceutical and biotech production.

What is the production capacity of the Automatic Vial Filling and Plugging Machine?

The machine is available in multiple models with the following outputs:

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

The actual speed depends on vial size and liquid viscosity. All models deliver consistent filling accuracy of ±1% (with options for ±0.5% to ±1%).

What vial sizes can the Automatic Vial Filling and Plugging Machine handle, and how easy is changeover?

The machine supports a wide range of vial sizes:

Filling Volume: 2ml to 250ml
Vial Diameter: 15mm to 70mm
Vial Height: 25mm to 140mm

It is suitable for both small and large batch production. Changeover between different vial sizes and fill volumes is quick and easy using minimum change parts. Volume adjustment is done simply by increasing or decreasing the piston stroke length, with variable AC frequency drive for speed control.

How does the Automatic Vial Filling and Plugging Machine ensure sterility and product quality?

Sterility is maintained through:

“No Vial – No Filling” and “No Vial – Machine Stop” systems to prevent contamination and wastage.
Diving nozzles for gentle filling that minimizes foaming and splashing.
All product contact parts made of Stainless Steel 316L (framework in SS 304).
Design compatible with Laminar Air Flow (LAF) protection and aseptic environments.
Optional CIP/SIP capability and full cGMP compliance with IQ/OQ documentation.

These features make the machine ideal for sterile injectable production as per USFDA, EU-GMP, and WHO guidelines.

What are the power requirements and key safety features of the Automatic Vial Filling and Plugging Machine?

Power requirements are model-specific:

ALVF-40: 1 HP
ALVF-80: 1.5 HP
ALVF-120 & ALVF-250: 2 HP

(All models operate on 440 Volts, 3 Phase, 50 Hz – customizable as per customer requirements.)

Key safety and operational features include:

“No Vial – No Filling” and “No Vial – Machine Stop” systems with sensors.
Safety enclosures (acrylic covers).
Digital vial counter.
In-feed and out-feed turntables with stainless steel or Delrin slats.
Easy accessibility for cleaning and low maintenance.

The machine integrates seamlessly with vial washing, sterilization, capping, and labeling equipment for a complete production line.

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