Automatic Vial Filling and Stoppering Machine

Q: What are the available models and production capacities?

We offer four models based on production requirements: ALVF-40 (2 filling heads): Up to 40 vials per minute ALVF-80 (4 filling heads): Up to 80 vials per minute ALVF-120 (8 filling heads): Up to 150 vials per minute ALVF-250 (12 filling heads): Up to 250 vials per minute Actual output depends on vial size, fill volume (2ml to 250ml), liquid viscosity, and stopper size. The machine supports vial diameters from 15mm to 70mm and heights from 25mm to 140mm.

Q: What compliance standards and safety features does the machine have?

The machine is fully cGMP compliant and compatible with USFDA, EU-GMP, and WHO guidelines. All product contact parts are made of SS 316L and the framework of SS 304 . Key safety and validation features include: Laminar airflow compatibility Acrylic safety covers “No Vial – Machine Stop” system IQ/OQ documentation Optional PLC with touch screen HMI and password-protected counters Vacuum-type stoppering with half-stoppering capability It is ideal for sterile production environments and integrates easily with vial washing and capping machines.

Description

Injectable liquid vials are filled and rubber-stoppered using the compact type Automatic Vial Filling and Stoppering Machine (vial filler). Adinath provides a variety of vial filling machine models that are appropriate for the pharmaceutical sector. The main structure of the Automatic Vial Filling and Rubber Stoppering Machine is protected by a safety acrylic cover made of stainless steel, laminar air flow, an in-feed turntable, a peristaltic pump filling machine, a Delrin Slate conveyor, an outfeed turn table, a vibrator bowl and rubber stopper chute, pneumatic parts, an electrical panel, an AC drive, a PLC, and an HMI.

With a maximum speed of 40 vials per minute, the Model ALVF Automatic Vial Filling and Stoppering Machine is appropriate for round vials. Depending on the type of liquid, vial neck size, fill volume, and rubber stopper size, the machine can produce up to 250 vials per minute. The entire machine construction, including the machine frame structure, is finished in stainless steel. For more efficient operation, the machine has built-in Turn Tables at the In-feed and Out-feed with separate motors to match the speed of entering and outgoing vials. Every component that comes into touch with rubber stoppers and liquids is composed of SS 316 materials. Additionally, the machine has a rubber stoppering system of the vacuum-type.

We are also manufacturer of Automatic Vial Washing Machine, Automatic Vial Linear Washing Machine, Automatic Vial Cap Sealing Machine, Automatic Vial Capping Machine, Inectable Dry Powder Filling Machine, Automatic Injectable Liquid Filling Machine, High Speed Vial Filling Machine, Automatic Pharmaceutical Vial Filling Machine, Automation Vial Filling, Stoppering and Cap Sealing Machine, Automatic 2/4/6/8/12 Head Vial Filling & Rubber Stoppering Machine.

Salient Features of Automatic Vial Filling 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 Automatic Vial Filling and 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 Automatic Vial Filling and 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 Automatic 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 of Automatic 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 an Automatic Vial Filling and Stoppering Machine?

An Automatic Vial Filling and Stoppering Machine is a compact monoblock system designed for aseptic filling of sterile liquid formulations (such as injectables, vaccines, and serums) into glass vials, followed by precise rubber stoppering. It integrates filling and stoppering in one unit under laminar airflow to prevent cross-contamination. The machine is cGMP compliant and suitable for small to large batch production in the pharmaceutical, biotech, and cosmetic industries.

What are the available models and production capacities?

We offer four models based on production requirements:

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

Actual output depends on vial size, fill volume (2ml to 250ml), liquid viscosity, and stopper size. The machine supports vial diameters from 15mm to 70mm and heights from 25mm to 140mm.

What is the filling accuracy and what technologies are used?

The machine delivers high filling accuracy of ±1% (with options for ±0.5%). It uses piston pumps or peristaltic pumps (CIP/SIP capable) with SS 316L syringes/nozzles. Features like “No Vial – No Filling,” suck-back system (to prevent dripping), and independent head operation ensure precision and minimal product wastage. Optional nitrogen flushing is available to reduce oxidation.

Does the machine require change parts for different vial sizes?

No, our Automatic Vial Filling and Stoppering Machine is designed with minimal or no change parts required for different vial sizes and fill volumes. This allows quick changeover, easy adjustment for vial height, and reduced downtime. It also features a PRIME function for fast suction and cleaning of the filling material.

What compliance standards and safety features does the machine have?

The machine is fully cGMP compliant and compatible with USFDA, EU-GMP, and WHO guidelines. All product contact parts are made of SS 316L and the framework of SS 304. Key safety and validation features include:

Laminar airflow compatibility
Acrylic safety covers
“No Vial – Machine Stop” system
IQ/OQ documentation
Optional PLC with touch screen HMI and password-protected counters
Vacuum-type stoppering with half-stoppering capability

It is ideal for sterile production environments and integrates easily with vial washing and capping machines.

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