Automatic Vial Filling & Stoppering Machine

Automatic Vial Filling and Stoppering Machine (vial filler) is uses for the filling and rubber stoppering of injectable liquid vials. Adinath provides a variety of Vial Filling Machines those are appropriate for use in the pharmaceutical sector. Our Automatic Eight Head Vial Filling Machine can fill up to 12000 vials per hour, which is suitable for medium-sized batches. Our Automatic Two/Four Head Vial Filling Machine can fill up to 3600 to 7200 vials per hour, which is appropriate for medium-sized and small batches. Our Automatic Twelve Head Vial Filling Machine can fill up to 18000 vials per hour for large batch productions. Our vial filling machines adhere to cGMP regulations and are simple to use. In addition to the stainless steel piston pump that comes standard with our machine for liquid filing, we can also provide peristaltic pumps upon special customer request for even more filling precision.

Vial filling machine is effective equipment for filling sterile liquid into glass vials. Bulk loading of vials can be performed onto infeed turn table of the machine. Vials then accumulate and transferred one by one to conveyor belt of the machine. During movement vials reaches to the filling station. Filling station is having nozzles for nitrogen purging and liquid filling operations. According to filling head one/two/four/six/eight/twelve filling nozzles installed onto machine for filling operations. At filling station machine performs nitrogen flushing, liquid filling and nitrogen flushing operations in sequential manner. Once filling is done then vials transferred to stoppering unit for stoppering operations.

Machine equipped with inbuilt rubber stoppering unit for rubber bunging operations. After filling vials transfer to rubber stoppering station where vial pick up stoppers one by one from the stopper chute. Further vial passes through below SS 316L roller which in turn stopper pressing operations. Duly stoppered vials further get collected on exit end of conveyor for further capping operations.

The main structure of the Automatic Vial Filling Machine includes an SS cabinet, a safety cabinet with a door, a laminar air flow unit, an infeed turn table, a conveyor belt with Delrin slats for a piston or peristaltic pump, an outfeed turn table, a vibrator bowl and chute for rubber bungs, pneumatic modules, and an electrical control panel with an AC drive, PLC, and HMI.

We have option of CE mark machine upon specific user requirements. We can also provide 21 CFR Part 11 automation package for specific requirements. We provide IQ, OQ, DQ validation protocols for pharmaceutical GMP requirements. We provide lifetime support of spare parts for our supplied machines.

Automatic Vial Filling & Stoppering Machine Video

Salient Features of Automatic Vial Filling & Stoppering Machine

• No cross contamination.
• Suitable for the filling Volume of 2ml to 250ml.
• Piston pump/Peristaltic pump aseptic filling.
• Filling with accuracy of ±0.5-1%.
• Easy to validate filling system for small/large batch production.
• All Contact Parts Made from S.S 316L & framework by S.S. 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 to comply vial filling machine validation process.
• PLC with Graphical User Interface. (Optional)
• PRIME is a distinctive feature that allows you to quickly suck filling material from the storage tank to the nozzle end. This feature is also beneficial for cleaning the filling line (silicon tubing) and filling the peristaltic pump in both directions.
• The machine can use the PRIME function for all peristaltic pumps together or for individual peristaltic pump.
• Filling is done with a specifically built filling peristaltic pump which has CIP and SIP ability.
• Individual pumps may be calibrated and adjusted for the desired volume using a simple PLC.
• Because of a particularly built peristaltic pump with suck back capability, oil-based materials can also be run without dripping.
• Each filling head may operate independently, allowing the machine to operate constantly without sacrificing significant production.
• Bung orientation bowl and discharge chute with built-in vibrator. For use with wet bungs, we offer bung orienter bowl and chute with Teflon coating.
• Bungs are held in a specifically designed vacuum bung hold disc, which then discharges the bung evenly onto the vial. The bung pressing roller evenly presses the bungs.
• Half stoppering can be done with the same Rubber bunging machine assembly.
• Each filling head may operate independently, allowing the machine to operate constantly without sacrificing significant production.
• For varied sizes of vials and filling volumes, no change parts are necessary.
• Because mechanical parts like syringe sets, Teflon seals, gears, and chains are rarely used, there is relatively little product variation over time.
• PLC with simple controls for volume and speed adjustments.
• The entire assembly can be adjusted upwards and lower to accommodate different heights of vials.
• PLC alarms for “No Vial, Machine Stop” and “No Vial, No Bung.”
• For daily track reports and planning, a password-protected production counter is provided.
• The errors can be recognized on the touch screen HMI of the PLC and readily attended to.
• To avoid the negative effects of the electric supply, the machine is supplied with an isolated power source.
• Well known mechanical components such as FESTO/Janatics pneumatics and CE approved electrical/electronic components such as Bonfiglioli/Crompton AC motors, Allen Bradley drives, PLC & HMI Touch screen, Sensors, MCB’s, relays, and other components.

Process Operation of Automatic Vial Filling Machine

The incoming dry vials (sterilized and siliconised) are fed through the in-feed turn table and suitably guided on the moving Stainless Steel slat conveyor belt at the required speed of the correct placement below filling unit.

The filling unit consists syringes & nozzles. Syringes are made of Stainless Steel 316L material for cGMP compliance. Vials stop below filling unit with centering of filling nozzles, during stoppage nozzles discharge pre determined liquid into vials. Duly filled vials delivered on stoppering unit which is mounted on same platform.

Stoppering Unit consist Bowl and Chute designed for desired stopper / bung size. Stoppers are stored in vibratory bowl and delivered to the vial through delivery chute. Vibratory bowl is equipped with special vibrator motor. Stoppers travel in vibratory bowl support guide through vibration. There is arrangement in the bowl in which wrong position stopper get rejected in travelling and only correct position of stopper get into chute. Further stoppers hold at delivery point of chute through spring which collected one by one by vial in traveling below the chute. Further there is one Stainless Steel 304 roller installed to press the stoppers. Vial transfer below the wheel in which get stoppered.

Duly stoppered vials further move on conveyor & collected on out feed turn table (optional) or on to conveyor of vial aluminum cap sealing machine for cap sealing operations.

Technical Specification of Automatic Vial Filling Machine

* 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.