This Automatic Vial Filling and Rubber Stoppering Machine is a sophisticated machine for filling and sealing injectable liquids in glass vials. Commonly used in the pharmaceutical industry, this machine ensures its fill volumes are accurate, stoppers are placed correctly, and product integrity and sterility are upheld.
Vial Filling and Rubber Stoppering Machine Video
Build to Sustain and Adhere
Built according to industrial standards using stainless steel, the Automatic Vial Filling and Rubber Stoppering Machine is designed for robust manufacturing environments. All Contact Parts are of SS 316L, cGMP Compliant & Easy to Clean & Sterilize.
How It Works?
The Automatic Vial Filling and Rubber Stoppering Machine works on a few very well-timed and coordinated steps that include:
Vial Feeding: Sterilized dry vials are siliconized before being fed through an in-feed turntable onto a stainless steel slat conveyor—ensuring proper placement in line under the filling unit.
Filling Process: The filling unit consists of SS 316L syringes and nozzles, which fill a predetermined volume of liquid into each vial with an accuracy of ±1%. The diving nozzle system reduces foaming when filling.
Automated Orientation and Feeding of Stoppers: Rubber stoppers are fed via a vibratory bowl and chute system to ensure proper positioning and orientation. Stoppers are then dropped into precise locations on each vial as filled vials pass beneath the chute.
Stopper Feeding and Placement: A stainless steel roller applies an equal amount of pressure on the stoppers used in the vials for a hermetic seal.
Vial Discharge: After sealing, these vials pass to the out-feed turntable or chute and then towards the next station (capping, labelling, etc.), automatically in a continuous production process.
User-Centric Features
The machine boasts an intuitive control panel, allowing operators to monitor and adjust critical parameters such as fill volume and production speed. Safety features include an emergency stop system and protective guards, ensuring a secure operating environment. Additionally, the machine offers quick changeover capabilities, reducing downtime between production batches.
Key Features of Vial Filling and Rubber Stoppering Machine
Without Cross Contamination: This guarantees a clean and sterile production of the needle for every single unit.
Filling range: From 2ml to 100ml, fits all sizes of vials.
Precise filling: Piston pump or peristaltic pump aseptic filling of ±1%.
Batch Flexibility: Filling system ideal for both small and large batch production with simple validation.
Construction: Contact parts are made from SS 316L, while the framework is made up of SS 304, providing durability and easy compliance.
Smooth Speed Control: Variable A.C. frequency drive for speed adjustment as per production need.
Digital Vial Counter: Counts production output for accurate tracking efficiency.
Automatic Feeding System: In-feed Turn Table/Unscrambler — Automatic feeding of vials with smooth automatic feeding.
On-Line Mechanism: Reduces human interference and integrates within the production line.
No Vial – No Filling System: Avoids wastage by halting the filling procedure when no vial is present.
IQ/OQ Documentation: Compliance documentation can be produced for the validation of the fill and seal machine.
Non-Drip Filling: Materials are processed without dripping by a peristaltic pump with a suck-back function.
Seamless Filling: No change parts are needed for different vial sizes and fill volumes.
Use half-stoppering: Half stoppering system can be incorporated when ordered before ordering process.
Reduced Maintenance: A reduced number of moving mechanical parts (e.g., syringe sets, Teflon seals, gears/chains) means less long-term variation and maintenance.
Adjustable Height: The whole filling assembly can be moved up and down for vials of different heights.
Advanced PLC Alarms: Alerts such as No Vial – Machine Stop and No Vial – No Bung reduce the losses of operational efficiency. Touchscreen HMI identifies errors easily.
Production Tracking: A daily report from a password-protected production counter that helps with better planning.
Stable Power Supply: Isolated power source so the power fluctuations do not affect machine performance.
High-end components: FESTO pneumatics and CE-approved electrical/electronic components:
- Delta/Fuji make drives
- PLC & HMI touchscreen
- Bonfiglioli/Crompton/similar AC motors
- Quality sensors, MCB relays, etc., made with industrial-grade components.
With such a wide range of features, the Automatic Vial Filling and Rubber Stoppering Machine provides unrivalled accuracy and efficiency along with high reliability in any of the pharmaceutical productions.
Technical Specification of Vial Filling Machine
|
Model |
ALVF-40 | ALVF-80 | ALVF-120 | ALVF-250 |
| Filling Heads | Two | Four | Eight |
Twelve |
|
Production Rate |
Up to 20 vials/min | Up to 40 vials/min | Up to 100 vials/min | Up to 250 vials/min |
| 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. |
| Dimensions | 2050mm x 850mm x 1700mm | 2200mm x 850mm x 1700mm | 3000mm x 945mm x 1700mm |
3500mm x 945mm x 1700mm |
* 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.
*The specs guarantee fast and accurate filling to meet pharmaceutical production requirements.
The Automatic Vial Filling and Rubber Stoppering Machine is a valuable asset to any pharmaceutical manufacturing process, delivering precision, efficiency, and compliance with industry standards. It boasts an array of advanced features and a sturdy construction that guarantees reliable performance, so it is ideal for facilities looking to upgrade their capabilities in the production of injectable liquids.
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