Liquid Vial Filling Machine

Integrated Stopper & Cap Assembly Machine: Complete Solution for Liquid Vial Packaging

Introducing the Integrated Stopper & Cap Assembly Machine, an innovative vial filling system engineered to revolutionize the packaging of liquid pharmaceuticals, vaccines, and sensitive diagnostics. This advanced liquid vial filling machine uniquely combines three critical processes—aseptic liquid filling, automatic rubber stopper insertion, and screw cap application—into a single, compact, and synchronized unit. Designed for small to medium batch production, this all-in-one vial liquid filling machine streamlines the packaging of injectables, ophthalmics, and high-value biologics by eliminating separate equipment and manual handling between filling, stoppering, and capping stages.

capping part   The capping part of the inner-stopper and outer-cap 3-in-1 small vial filling machine is designed to complete both stopper insertion and outer cap sealing with high precision. After filling, each vial is accurately positioned for automatic placement of the inner stopper, followed by secure application of the outer cap. The system ensures stable alignment and consistent force during the capping process, preventing leakage and protecting vial integrity. With servo-controlled motion and reliable cap feeding mechanisms, the capping module delivers uniform sealing quality across all vials. Constructed from GMP-compliant materials, it guarantees hygienic operation and dependable performance for pharmaceutical small-vial production.

Unified Process for Enhanced Sterility and Efficiency

This integrated system redefines efficiency in vial packaging by performing consecutive operations within a single controlled environment. The process begins with precision liquid dispensing via a peristaltic or piston pump, ensuring accurate fills from 0.5mL to 50mL with ±0.5% accuracy. Immediately after filling, the machine automatically places and seats a sterile rubber stopper (lyophilization or solution type) onto the vial mouth. Finally, a screw cap (e.g., flip-off, tear-off) is applied and crimped over the stopper to ensure a tamper-evident, hermetic seal. This seamless workflow makes it an ideal vial filling system for potent compounds, clinical trial materials, and sterile products where minimizing exposure and manual intervention is critical.

Engineered for Aseptic and Containment Applications

Built as a dedicated liquid vial filling machine for regulated environments, the system features a hygienic design with 316L stainless steel construction and polished surfaces compatible with cleanroom protocols. Optional integration with laminar airflow units or isolators enables compliance with aseptic processing requirements. The closed fluid path, often utilizing single-use tubing assemblies, prevents cross-contamination and simplifies product changeover. As a robust vial liquid filling machine, it supports full Clean-in-Place (CIP) and Sterilize-in-Place (SIP) capabilities, ensuring readiness for sterile manufacturing.

Core Features & Technological Advantages

• Tri-Function Integration: Combines high-precision liquid filling, automatic stopper placement, and screw cap application in one machine footprint, reducing complexity and floor space requirements.

• Aseptic & Containment Ready: Designed for Grade C cleanrooms with optional Grade A integration, featuring smooth surfaces, minimal particle generation, and containment options for potent compounds.

• Precision & Flexibility: Servo-driven filling system ensures accuracy across a broad volume range, with quick-change tooling for different vial sizes (2R–20R), stoppers, and caps.

• Regulatory Compliance: Equipped with a 21 CFR Part 11-compliant PLC and HMI for recipe management, electronic batch records, and audit trail logging across all three functions.

• Reduced Operational Risk: Eliminates manual transfer between filling, stoppering, and capping, significantly lowering contamination risk and improving operator safety.

Ideal Applications

• Sterile Injectables: Vaccines, antibiotics, biologics, and hormone solutions in vials.

• Lyophilized Products: Filling and stoppering for freeze-dried pharmaceuticals prior to lyophilization.

• Ophthalmic & Otic Solutions: Sterile eye/ear drops in sealed vials.

• Diagnostic Reagents: Liquid calibrators, buffers, and assay controls requiring hermetic seals.

• Clinical Trial Manufacturing: Small-batch production of investigational drugs with complete container closure.

Your Partner in Integrated Vial Packaging

We provide end-to-end support for this advanced vial filling system, from initial application testing and factory acceptance to on-site installation, operational qualification (OQ), and performance qualification (PQ). Our team ensures this liquid vial filling machine is optimized for your specific container-closure system and meets all regulatory requirements for sterile or potent drug manufacturing.