Glass Vial Filling Machine

Q: Can one machine handle different vial sizes and fill volumes?

Yes, these machines are designed for versatility. By using change parts (such as star wheels, feed worms, and syringes), a single machine can be adjusted to handle various vial diameters and fill volumes, ranging from 2 ml to 100 ml . Transition times are usually kept low to maintain production efficiency.

Q: What is the difference between a piston pump and a peristaltic pump filler?

Piston Pumps: Best for high-speed, high-accuracy filling of consistent liquids. They are durable but require thorough cleaning between batches. Peristaltic Pumps: Ideal for shear-sensitive or highly sterile products. Since the liquid only touches the tubing, it significantly reduces the risk of cross-contamination and simplifies the cleaning-in-place (CIP) process.

Q: Does the machine include bunging (stoppering) and capping?

While standalone fillers exist, most industrial models are monoblock systems . This means the machine performs filling, rubber stoppering (bunging), and sometimes aluminum cap sealing on a single base. This integration reduces the footprint and minimizes the exposure of the open vial to the environment.

Description

Glass Vial Filling Machine is suitable for both liquid filling and rubber stoppering injectable vials. The pharmaceutical and chemical industries utilise vial filling and bunging machines to automate the filling and sealing of glass vials with injectable liquid or powdered solid materials. Attractive matt-finished stainless steel is used to finish the machine. The basic unit consists of turntables, S.S. Stat conveyor belts, special eccentric pre-gassing, filling, and post-gassing. S.S. 316 Syringes have a compact, conveniently accessible panel and non-toxic synthetic rubber tubing, making them extremely precise and effective.

The close closeness of filling and stoppering machinery reduces the possibility of contamination. The devices are designed to be utilised in a sterile environment with laminar flow protection. The un-scrambler itself has been cleared of dead ends and difficult-to-clean regions. A sophisticated automated device, the Glass Vial Filling Machine is intended to administer pharmaceuticals under sterile circumstances. Accuracy and versatility are increased when using a glass vial filling machine. Furthermore, it enhances the process’s sterility. Additionally, it lowers the possibility of drug contamination. For the pharmaceutical sector, the glass vial filling machine is a crucial and essential piece of machinery.

The operation is usually a continuous or intermittent motion process that follows these key stages:

In-feed: Vials are loaded onto a rotating turntable or a conveyor belt.

Sterilization/Cleaning: Before reaching the filling needles, vials often pass through a tunnel where they are cleaned with de-ionized air or sterilized via heat.

Filling: The vials move under a series of filling heads. Depending on the liquid’s viscosity and required precision, the machine uses different pump types (like peristaltic or piston pumps) to dispense the exact volume.

Stoppering: Immediately after filling, a rubber stopper is partially or fully inserted into the neck of the vial.

Capping/Sealing: An aluminum cap is crimped over the stopper to create a hermetic (airtight) seal.

Discharge: The finished vials are moved to the labeling or packaging station.

Salient Features of Glass 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 Glass 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 Glass Vial 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 Filling Machine

Advantages of Glass Vial Filling Machine

High Precision and Accuracy

Maintaining Sterile Integrity

Product Protection and Stability

Versatility and Scalability

Compliance and Data Logging

Key Components of Glass Vial Filling Machine

Filling Needles: Stainless steel tubes that descend into the vial to minimize splashing and foaming.

Dosing Pumps: The “heart” of the machine; determines the accuracy of the fill volume.

Star Wheels: Rotating gears that move individual vials through different stations with precise timing.

Vibratory Bowl: Aligns and feeds rubber stoppers or aluminum caps into the assembly line.

Sensors (No Vial-No Fill): A safety feature that ensures the machine doesn’t dispense expensive medicine if a vial is missing.

FAQ for Glass Vial Filling Machine

What is the typical filling accuracy of a Glass Vial Filling Machine?

Most modern automatic glass vial filling machines offer high precision, typically within a range of ±0.5% to ±1%. This accuracy is achieved through advanced piston pumps or peristaltic pump systems, ensuring minimal product wastage—which is critical for high-value pharmaceutical liquids.

Can one machine handle different vial sizes and fill volumes?

Yes, these machines are designed for versatility. By using change parts (such as star wheels, feed worms, and syringes), a single machine can be adjusted to handle various vial diameters and fill volumes, ranging from 2 ml to 100 ml. Transition times are usually kept low to maintain production efficiency.

How does the machine ensure sterile conditions during the filling process?

To meet strict cGMP standards, glass vial filling machines are often equipped with:

Laminar Air Flow (LAF) units to maintain a Class 100 environment.
No-Vial-No-Fill sensors to prevent spillage and contamination.
Stainless Steel 316L contact parts for easy sterilization and corrosion resistance.

What is the difference between a piston pump and a peristaltic pump filler?

Piston Pumps: Best for high-speed, high-accuracy filling of consistent liquids. They are durable but require thorough cleaning between batches.
Peristaltic Pumps: Ideal for shear-sensitive or highly sterile products. Since the liquid only touches the tubing, it significantly reduces the risk of cross-contamination and simplifies the cleaning-in-place (CIP) process.

Does the machine include bunging (stoppering) and capping?

While standalone fillers exist, most industrial models are monoblock systems. This means the machine performs filling, rubber stoppering (bunging), and sometimes aluminum cap sealing on a single base. This integration reduces the footprint and minimizes the exposure of the open vial to the environment.

Countries We Export to

Partner with Industry Experts

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.

GET A QUOTE!