The vial filling machines is extensively used in the pharmaceutical industry to fill vials with medicinal ingredients. These highly durable machines are designed to perform the precise operation of expeditious vial filling. Vial filling machines also contain multiple filling heads that help them to achieve a higher filling rate and increased productivity to meet the demands of the pharmaceutical industry. There are many variants of vial-filling machines suitable for different applications in the pharmaceutical industry.
Vial Filling Machine Working Principle
The vial filling machine contains the SS slat conveyor for the effortless moving of the vials on the filling machine. From the conveyor belt, the empty sterilized vials are then transferred to the filling station, where the required pharmaceutical ingredients are filled in precise quantities. The filling stations contain multiple heads or nozzles that enable faster vial filling without waste. The number of filling heads from 2 to 20 could be customized as per the manufacturing requirement. The vials get precisely filled by the filling heads, after which the filled vials get transferred to the next station on the filling line. The machine maintains consistent sterility throughout the filling operations. At the next station, stoppers are placed over the head of the vials. This ensures that h sterility and integrity of the components s preserved. During the filling process, it is crucial to ensure that the pharmaceutical ingredients and vials are free of contaminants. Any disturbance with the chemical composition of the components could jeopardise the entire batch of filled vials and may even result in the rejection of the whole batch. The stoppers are then capped and sealed before going to the labeling station.
Types of Vial Filling Machines
It is prudent to understand different types of vial filling machines available and their design, application and working process. In below we are describing different types of vial filling machines with information thereof:
Vial Filling Machine
The pharmaceutical vial filling machine used in the pharmaceutical industry is also called the injectable vial filling machine and includes the vial filler and the rubber stoppers. These automatic vial-filling machines ensure consistency in volume, reduce product losses, and comes with a built-in quality control system for real-time volume checking of the vials. Pharmaceutical vial-filling machines are utilized in both sterile and non-sterile applications.
Vial Liquid Filling Machine
The vial liquid filling machine consists of the main machine, unscrambler, conveyor, stopper feeding bowl and scrambler. The conveyor belt transfers the vials towards the filling station, where the liquid contents are filled into the machine. Vial liquid filling machines fill liquids or fluids of various viscosities into the vials. These machines are widely used in the pharmaceutical industry to ensure the precise filling of the vials. The vials liquid filling machine works on the diving nozzle and volumetric principle, which provides sterile and precision filling operations.
Vial Powder Filling Machine
The vial powder filling machine consists of the washing, sterilizing, filling, sealing and labeling operations. All the equipment is aligned on the filling line to ensure continuous production of the vials for the pharmaceutical industry. The automatic vial powder filling machine is crucial in the pharmaceutical industry because that helps fill granules or powder into the vials.
Injectable Liquid Filling Machine
The liquid filling line or machine functions under high pressure. Therefore, it could also be classified as liquid pressure filling. In this process, the liquid injectable flows into the storage bottle depending on the weight when the pressure in the fluid reservoir becomes equal to the air pressure in the bottle.
The injectable liquid filling lines are easy to operate and fill the precise amount of liquid into bottles, containers or gallons. The filling mechanism built into the machine allows it to adjust the filling rate and quantity per bottle size or container without replacing any components. These machines are equipped with sensors that can automatically stop the process without any bottle on the belt.
Vial Filling and Bunging machine
The vial filling and bunging machine consist of the conveyor, safety guard, pneumatic cylinders, motor and gearbox. The machine is designed to protect pharmaceutical ingredients from contamination or mishap. The vial filling and bunging machine are extremely useful in the pharmaceutical industry where rapid, large scale, sterility and precision are the norm during production.
Vial Packaging Line
Vial Filling Packaging process is incomplete without cap sealing, capping, washing and labeling operations, so it is important to understand design and operation of these machines also. After having approach of vial filling machines below are the information of vial capping machine, vial washing machine and vial production line:
Vial Capping Machine
The automatic vial capping machine is ideal for sealing circular vials and can achieve a top speed of 240 vials per minute depending on the vial height, vial width, and cap type. The machine could also be used for tubular or melded glass Vials with Flip seals and flat aluminium seals, with a specific change of pieces available for both capping styles.
The vial capping machine comes with the star wheel, a single engine to synchronize the conveyor and the adjustable conveyor belt height feature.
Handheld vial cappers are perfectly suitable for securing aluminium caps over aluminium or glass vials. These capers are widely utilized in microbiology and pharmaceutical laboratories for testing purposes.
Vial Cap Sealer or Vial Filling and Sealing Machine
A fully automated vial cap sealer or the vial cap sealing machine is most suitable for cap sealing operations over injection glass vials in the pharmaceutical industry. The vial cap sealing machine can be easily connected with the vial filling machine and the vial labeling machine to become one whole vial filling line production unit.
The vial filling and sealing machine is part of the vial filling line and perfectly seals the filled vials with plastic or aluminium caps swiftly and effectively. The frame of the vials sealing machine is made of stainless steel, making the entire unit versatile and compact as per the GMP standards and specifications.
Vial Filling Line
The vial filling line combines the vial washing machine, the dehydrogenation tunnel, and the vial filling machine into one production line. This arrangement makes the filling line appropriate for lyophilized and liquid filling operations. Vial filling lines are extensively used in the pharmaceutical industry to fill vials with pharmaceutical ingredients. The vial filling line also includes the rubber stoppering machines or vials sealing machines required for packing the vials after their careful packing with the medical components.
Vial Washing Machine
Compact nozzles blow high-pressure air to remove any leftover fluids from the exterior ceramic surface of the vials. The external vial washing machines are manufactured to deliver high-performance washing, cleaning and sealing operations. They ensure washing fluids are thoroughly removed from the vials and the vials are effectively decontaminated for the filling process.
Vial washing machines are perfectly designed with high-tensile strength materials to deliver user-friendly, high-speed vial washing and delivery operations.