Vial Filling Line

16-Head "Tracking" Precision Filling System: Complete Integrated Vial Line for Aseptic and Sensitive Liquid Packaging

Engineer a seamless, high-precision production workflow with our 16-Head "Tracking" Precision Filling Line, a sophisticated, integrated system comprised of an Automatic Bin Unscrambler and a 16-Head "Follow-the-Vial" Filling Machine. Designed specifically for pharmaceutical, biotech, and diagnostic applications, this complete vial packaging line automates the entire process from bulk container handling to precise, peristaltic filling, significantly reducing contamination risk and human intervention. The system's core innovation lies in its synchronized "tracking" motion, where the filling nozzles descend into and move with each vial during the dosing cycle—a technology derived from advanced parenteral production—making it an exceptionally gentle and accurate vial line machine for sensitive solutions, suspensions, and sterile products.

bottle unscrambler    The bottle unscrambler of the 16-head tracking filling line automatically orients and feeds bottles smoothly, ensuring a continuous, stable flow for high-speed, efficient filling operations.

filling part   The filling section of the 16-head tracking filling line delivers precise, high-speed dosing with synchronized nozzles, ensuring accurate, consistent liquid filling for efficient production.

A Fully Integrated, Closed-Loop Production Cell

This line represents more than just individual machines; it is a harmonized vial filling line engineered for optimal performance and compliance. The process begins with the Automatic Bin Unscrambler, which gently orients and feeds empty vials from a bulk hopper onto a sanitized conveyor, eliminating manual sorting. Vials are then transported into the ISO 5 clean zone of the 16-head tracking filler. Here, each filling head precisely tracks the individual vial's motion, ensuring a consistent fill height and eliminating splash or foam formation—critical for oxygen-sensitive or high-value biologics. The line is designed for seamless future integration with downstream stoppering, capping, and sealing modules, providing a clear pathway to a fully automated vial packaging line.

Pharmaceutical-Grade Engineering for Critical Applications

Built to meet stringent cGMP and, where applicable, Annex 1 requirements, this vial line machine is constructed with 316L stainless steel and pharmaceutical-grade polymers for all product contact surfaces. The system features a hygienic design with rounded corners, sloped surfaces, and Clean-in-Place (CIP) / Steam-in-Place (SIP) capabilities. The peristaltic pump technology ensures absolute separation between the product pathway and the machine mechanics, preventing cross-contamination and simplifying validation. As a complete vial filling line, it offers optional integration with laminar airflow units or isolators to maintain the highest grade of aseptic processing for sterile products.

Core Features & Technical Advantages

• "Follow-the-Vial" Tracking Technology: Ensures pinpoint accuracy (≤ ±0.5%) and gentle handling for volumes from 1mL to 100mL, ideal for sensitive proteins and cell therapies.

• Integrated Bin Unscrambler: Eliminates manual vial handling, reduces particulate generation, and provides a consistent, automated feed to the filler.

• Closed-System Filling: Peristaltic pumps with single-use tubing sets offer the ultimate product protection, ideal for potent compounds and multi-product facilities.

• Regulatory-Ready Control System: Centralized PLC with a compliant HMI (21 CFR Part 11) provides recipe management, electronic batch records, and full audit trail functionality.

• High Throughput with Precision: 16 synchronized filling heads deliver efficient production speeds while maintaining the accuracy expected from a premium vial line machine.

Technical Specifications

• Output Speed: 60 - 120 vials per minute (dependent on fill volume and cycle time).

• Filling Volume Range: 1mL - 100mL (configurable).

• Filling Accuracy: ≤ ±0.5% of target volume.

• Vial Compatibility: Glass or polymer vials, ranging from 2R to 20R sizes.

• Process Environment: Designed for at least a Grade C background with optional Grade A integration.

Your Partner in Advanced Aseptic Processing

We provide more than just machinery; we deliver a validated packaging solution. Our support includes comprehensive FAT/SAT protocols, installation qualification (IQ), and operational qualification (OQ) assistance. Our experts will partner with you to ensure this vial packaging line is optimized for your specific product and meets all regulatory expectations.