Four Head Vial Filling Machine

Q: What is the production capacity of a Four Head Vial Filling Machine?

Typically, a four-head linear machine can process between 40 to 100 vials per minute . The exact speed depends on the fill volume, the neck diameter of the vial, and the viscosity of the liquid being filled.

Q: Is the machine compliant with international pharmaceutical standards?

Absolutely.Our machines are built to cGMP (current Good Manufacturing Practice) standards.All contact parts are made from Stainless Steel 316L , while non-contact structures utilize SS 304 , ensuring the machine is suitable for sterile environments and easy to validate.

Description

An innovative solution created to satisfy the demands of industrial applications is the Four Head Vial Filling Machine. The machine is perfect for companies that need high-quality output because it is built with precision and guarantees 100% accuracy in vial filling. It is user-friendly due to its automation grade, which enables smooth operation with little manual intervention. The device runs on electricity and is compatible with a variety of setups thanks to its support for both 220V and 440V voltage combinations. It has a sturdy silver finish and is both aesthetically pleasing and useful. The machine is brand-new, optimised for effective vial filling procedures, and built for long-term use. This is a great option if you’re looking for a dependable, high-performing machine to improve your production line.

One of the top producers of vial filling machines in India is Adinath. Our selection of vial filling machines can meet manufacturing output requirements ranging from 20 VPM to 300 VPM. Every one of our machine models complies with GMP regulations. We produce machines either strictly in accordance with customer specifications or in accordance with our regular machine types. For the equipment we supply, we offer IQ, OQ, and DQ validation protocols. Depending on the needs of a particular customer, we can provide a machine model with a 21 CFR Part 11 automation package. While our high-speed vial filling machine can fill up to 300 VPM, our tiny vial filling machine can only fill up to 20 VPM.

Vial Feeding: Sterilized and siliconized vials are fed via an in-feed turntable or unscrambler onto a conveyor belt or star wheel system.

Filling Process: Vials are positioned under four independent volumetric filling nozzles. The nozzles use a cam mechanism for up-and-down movement, descending to fill during star wheel rotation and ascending post-fill. Each head operates autonomously for continuous production.

Stoppering: Filled vials move to the rubber stoppering station, where a vibratory bowl feeder orients and supplies rubber bungs. A spring-loaded pressing roller or vacuum hold disc ensures precise placement.

Output: Vials are then transferred to an out-feed turntable for sealing, labeling, or further processing. The entire cycle is synchronized for seamless inline operation.

Salient Features of Four Head Vial Filling Machine

Suitable for the filling Volume of 2ml to 250ml.
Piston pump/Peristaltic pump aseptic filling.
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 Four Head Vial 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 Four Head Vial Filling Machine

Model	ALVF-80
Filling Heads	Four
Production Rate	Up to 80 Vials/Minute
Vial Diameter	15mm to 70mm
Vial Height	25mm to 140mm
Filling Precision	±1%
Power Required	1.5 H.P.
Electrical Characteristics	440 Volts, 3 Phase, 50 Hertz
Overall Dimension	2200mm (L) x 850mm (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 Four Head Vial Filling Machine

Enhanced Production Speed

High Filling Accuracy

Versatility and Adaptability

Compact Footprint

Compliance and Hygiene

Key Features of Four Head Vial Filling Machine

Compact Design: Fully constructed with stainless steel (SS 304/316) for durability and easy cleaning, including the frame, contact parts, and enclosures. It features an acrylic cabinet for visibility and protection.

Safety Mechanisms: Equipped with a “No Vial, No Fill” system to prevent liquid wastage and a special clutch for detecting overturned or oversized vials, halting operations to avoid damage.

Drive System: Powered by high-quality imported gear motors for vibration-free performance and no oil leakage.

Customization Options: Available with stainless steel piston pumps for standard filling; peristaltic pumps can be added for higher precision. Nitrogen flushing before/after filling is optional for oxygen-sensitive products.

Sterile Operation: Designed for use under laminar flow hoods, with minimal distance between filling and stoppering units to reduce contamination.

FAQ for Four Head Vial Filling Machine

What is the production capacity of a Four Head Vial Filling Machine?

Typically, a four-head linear machine can process between 40 to 100 vials per minute. The exact speed depends on the fill volume, the neck diameter of the vial, and the viscosity of the liquid being filled.

Can this machine handle different vial sizes and fill volumes?

Yes. These machines are designed for versatility. Most models can handle vial sizes ranging from 2ml to 100ml. While some adjustments and “change parts” (like star wheels or guides) may be required for different diameters, the fill volume is easily adjusted via the PLC touch screen or syringe settings.

How accurate is the filling process?

Modern four-head fillers are highly precise, generally offering a filling accuracy of +1%. This is achieved through high-quality piston pumps or peristaltic pump systems, ensuring minimal loss of expensive pharmaceutical products.

Is the machine compliant with international pharmaceutical standards?

Absolutely.Our machines are built to cGMP (current Good Manufacturing Practice)standards.All contact parts are made fromStainless Steel 316L, while non-contact structures utilize SS 304,ensuring the machine is suitable for sterile environments and easy to validate.

Does the machine include “No Vial – No Fill” safety features?

Yes. A standard safety feature in our four-head model is the “No Vial – No Fill” sensor system. This ensures that the filling nozzles will not discharge liquid if a vial is missing from the conveyor, preventing product wastage and keeping the machine surface clean.

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