Automatic Vial Liquid Filling Machine

Description

Automatic Vial Liquid Filling Machine (also known as the Injection Vial Filling Machine) is a small device that is intended to fill liquid injection vials used in pharmaceuticals. It also includes a stoppering machine. The monobloc machine known as a filler is capable of doing both filling and stoppering/bunging tasks on the same platform. For GMP compliance, all continuous parts are constructed from stainless steel or FDA-approved materials.

There are several filling pump alternatives that offer ±1% filling precision. Additionally, we provide a fully automated Vial Filling Sealing Labelling Line with our Vial Cap Sealing Machine and Vial Labling Machine. The output of our filler range is between 20 and 250 VPM. Another benefit of an automatic vial filling machine is that it can increase production. The end customers are able to maximise their production rate because of the filling process’s quickness. Additionally, because the machine is entirely automated, there is no need for breaks between each production phase. High production accuracy is also guaranteed by the machine’s automation.

According to cGMP criteria, the machine is built entirely of stainless steel, including the machine frame structure. 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. Rubber stoppers and all contact pieces that come into touch with liquids are made of SS 316 materials.

Vial Feeding: Empty vials are loaded and aligned on a conveyor.

Preparation: Vials pass through washing/sterilization under laminar airflow in a Class 100 cleanroom environment.

Filling: Needles or nozzles dispense the liquid at controlled speeds; nitrogen flushing may be added to displace oxygen and extend shelf life.

Closing: Stoppers are inserted, and caps are applied, often with 100% in-process verification.

Output: Filled vials are ejected for further processing at rates from 100–600 vials per minute, depending on the model.

Salient Features of Automatic 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 Automatic 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 Automatic 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 Automatic 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 Automatic 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 Automatic Vial Liquid Filling Machine

What is an Automatic Vial Liquid Filling Machine?

An Automatic Vial Liquid Filling Machine is a fully automated pharmaceutical equipment designed to precisely fill sterile liquids into glass vials. It integrates filling, rubber stoppering, and often sealing in a single continuous operation under aseptic conditions. These machines are ideal for producing injectable drugs, vaccines, antibiotics, and other parenteral liquid formulations while ensuring high accuracy, speed, and compliance with cGMP, FDA, and WHO standards.

What are the main advantages of an Automatic Vial Liquid Filling Machine?

Key advantages include:

Exceptional filling accuracy (±0.5% to ±1%)
High production output (up to 120–300 vials per minute depending on model)
Reduced human intervention, minimizing contamination risk in sterile environments
Significant labor and product waste savings
Consistent quality across batches with real-time monitoring
Easy integration into complete vial washing–sterilizing–filling–capping lines

Automation helps pharmaceutical manufacturers scale production efficiently while meeting stringent regulatory requirements.

What is the typical production capacity of an Automatic Vial Liquid Filling Machine?

Capacity varies by model and number of filling heads. Most machines offer:

40–80 vials per minute (2–4 heads) for small to medium batches
120–250+ vials per minute (6–12 heads) for high-speed commercial production

Output depends on vial size (typically 1ml to 50ml), liquid viscosity, and line configuration. Our models can be customized to match your required hourly output — feel free to share your batch size for the best recommendation.

How does an Automatic Vial Liquid Filling Machine ensure filling accuracy and sterility?

These machines use advanced dosing technologies such as peristaltic pumps, servo-driven piston pumps, or ceramic pumps for precise volume control. Features like diving nozzles (for foam-free filling), no-bottle-no-fill system, in-process weight checking, and automatic reject ensure accuracy within ±1% or better. The entire process occurs in ISO Class 5 / Grade A environments with RABS or isolator compatibility, using SS316L contact parts that are easy to clean and sterilize, maintaining product sterility and integrity.

What factors should I consider when choosing an Automatic Vial Liquid Filling Machine?

Important factors include:

Required production speed and batch volume
Vial size range and quick changeover flexibility
Liquid characteristics (viscosity, foaming, sensitivity)
Filling technology (peristaltic vs. piston pump)
Level of automation and integration with existing lines
Compliance with cGMP, FDA, EU-GMP, and cleanroom compatibility
After-sales support, spare parts availability, and maintenance

Our team can help you select or customize the right model based on your specific product and production needs.

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