Vial Filling and Plugging Machine

Automatic Vial Filling and Plugging Machine is suitable to fill injectable glass vials. The basic unit consists of turntable, Stainless Steel Stat conveyor belt, unique eccentric pre-gassing, filling and post-gassing. Highly efficient and precision built Stainless Steel 316L Syringes, non- toxic synthetic rubber tubing and easy reach compact panel.

The minimal distance between filling and stoppering units reduces the risk of contamination. The machines are designed for operation in a sterile area and for use under laminar flow protection. The un-scrambler itself has been redesigned to eliminate dead ends and difficult-to-clean spots

Salient Features

  • Compact cGMP model
  • Suitable for the filling 2ml to 250ml vials
  • Piston pump/Peristaltic pump aseptic filling
  • Filling accuracy of ±0.5%-1%
  • “No Vial - No Filling” system
  • “No Vial - Machine Stop” system
  • In-feed Turn Table/ Unscrambler attached with the machine for automatic feeding of objects
  • All Contact Parts Made from AISI SS 316L & framework by AISI SS 304
  • No cross contamination
  • Easy to validate filling system for small/large batch production
  • Variable A.C. frequency drive for speed adjustment
  • Digital Vial Counter for counting production output
  • On-line Mechanism
  • IQ/OQ validation documents
  • PLC system with Graphical User Interface. (Optional)

Process Operation

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/four/eight vials together on conveyor for rubber stoppering operation.

Stoppering unit consist of Starwheel, Vibrator unit and Bowl. The sterilized and siliconised 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

Model ALVF-60 ALVF-120 ALVF-250
Number of Heads Two Four Eight
Production Rate 30 to 60
Vials/Minute
60 to 120
Vials/Minute
120 to 240 Vials/Minute
Input Specification
  • Container Diameter:
  • Container Height:
  • Rubber Stopper:


15mm to 70mm
25mm to 140mm
13mm, 20mm & 28mm Butyl with the help of change part

Filling Range 2ml to 250ml
Filling Accuracy: ±0.5%-±1%
Power Supply 1 H.P. 1 H.P. 1.5 H.P
Electrical Characteristics 440 Volts, 3 Phase, 50 Hertz, 4 Wire System
Optional Accessories:
  • Programmable Logic Control (System) with MMI
  • Safety Cabinet covering full machine
Overall Dimension: 2050mm(L) x
800mm(W) x
1680mm (H)
2200mm(L) x 850mm (W) x 1680mm (H) 3000mm (L) x
945mm (W) x 1680mm(H)
  (Dimension include basic machine & 30” In-feed turn table)

Note:
* Electrical characteristics can be adjusted as per customer’s requirements
* Rights of technical improvement & modification reserved.
* Illustration & dimensions are shown for information purpose only.