Aseptic vial filling

"Wash-Fill-Spin" Tri-Function Vial Machine: Integrated Monoblock for Small-Batch Aseptic Production

Introducing the innovative "Wash-Fill-Spin" Tri-Function Vial Machine, a compact, all-in-one monoblock system that integrates vial washing, liquid filling, and screw capping into a single, streamlined unit. Designed as an ideal automatic vial filling machine for small to medium batch production, this system is specifically engineered for pharmaceutical laboratories, compounding pharmacies, and contract manufacturers requiring flexibility and containment. It provides a complete, closed-loop solution for the aseptic vial filling of injectables, ophthalmics, and other sterile liquids, combining multiple process steps to minimize handling, reduce contamination risk, and accelerate time-to-market for critical products.

capping part   The capping part of the 3-in-1 small vial filling machine provides secure and precise sealing immediately after the filling process. Vials enter the capping zone in a controlled and continuous flow, where the system automatically positions each cap and applies consistent torque to ensure a tight, contamination-free seal. The capping heads operate with stable, vibration-free motion to protect delicate glass vials, while the servo-driven mechanism maintains uniform sealing quality across every batch. Designed to meet pharmaceutical GMP requirements, this module offers reliable performance, leak-proof closure, and full compatibility with various cap types used in modern small-vial production.

washing part   The washing part of the 3-in-1 small vial filling machine ensures thorough and pharmaceutical-grade cleaning before filling begins. Each vial is automatically indexed into the washing station, where dedicated nozzles perform high-efficiency internal and external rinsing using purified water and compressed air. This multi-stage washing sequence removes particulates, residues, and potential contaminants with consistent precision. The vial holders stabilize each bottle throughout the process, preventing breakage and ensuring accurate alignment for subsequent filling. Engineered to meet GMP cleanliness standards, this washing module provides reliable, repeatable sanitation essential for sterile and high-quality small-vial production.

Consolidated Process in a Single Hygienic Enclosure

This unique machine eliminates the need for separate equipment and manual transfers between washing, filling, and capping stations. The process begins with an integrated ultrasonic or precision spray washing station that cleans and rinses vials using WFI or purified water. The cleaned vials are then transferred within the same protected enclosure to the filling zone, where a peristaltic or piston pump system ensures accurate, non-contact dispensing. Finally, vials move to the capping module where screw caps are automatically sorted, placed, and torqued to specification. This integrated approach makes it a highly efficient pharmaceutical vial filling machine, perfect for potent compounds, clinical trial materials, and personalized medicines where cross-contamination must be rigorously controlled.

Engineered for Critical Aseptic Applications

Built with aseptic vial filling principles at its core, the machine features a hygienic design with 316L stainless steel construction, smooth surfaces, and a configuration that supports integration with laminar airflow or isolator technology. The closed fluid path system, often utilizing single-use tubing sets, ensures absolute product separation and simplifies changeover and validation. As a compact automatic vial filling machine, it offers a smaller footprint than traditional separate lines while maintaining compliance with cGMP guidelines for sterile product manufacturing.

Core Features & Technical Benefits

• Integrated Triple Function: Performs vial washing, precise liquid filling, and automated screw capping sequentially within one machine frame, reducing operational complexity.

• Designed for Aseptic Processing: Hygienic design with options for HEPA-filtered air supply and easy sterilization (CIP/SIP capabilities) to support aseptic vial filling protocols.

• High Precision & Flexibility: Servo-controlled filling system offers accuracy within ±0.5% for volumes from 0.5mL to 100mL, with quick-change tooling for different vial and cap sizes.

• Closed System & Containment: Ideal for handling potent or cytotoxic drugs, minimizing operator exposure and environmental release.

• User-Friendly Control: Intuitive PLC-based HMI allows for recipe management, parameter setting, and data logging for all three functions (wash, fill, cap).

Ideal Applications

• Sterile Injectables: Small batches of vaccines, antibiotics, hormones, and biologics.

• Ophthalmic & Otic Solutions: Eye/ear drops in sterile vials.

• Clinical Trial Manufacturing: Preparation of investigational drug products for Phases I/II.

• Compounding & Hospital Pharmacies: Production of personalized sterile medications.

• Diagnostic Reagents & Buffers: Aseptic packaging of sensitive liquid reagents.

Your Partner in Flexible Sterile Manufacturing

We provide comprehensive support to integrate this versatile pharmaceutical vial filling machine into your operation. Our services include installation support, operational training, and guidance on validation strategies (IQ/OQ/PQ) to ensure the system meets your specific requirements for small-scale aseptic vial filling.