Vial Line

Fully Automated Washing, Drying, Filling & Stoppering Line for Infusion/Injection Vials

Introducing our state-of-the-art Integrated Vial Line, a seamless, high-speed automation solution designed for the sterile production of large-volume parenterals (LVPs) and small-volume parenterals (SVPs) in syringe and infusion bottles. This complete Vial Line Machine integrates four critical aseptic processes—precision washing, depyrogenation drying, aseptic filling, and sterile stoppering—into one continuous, synchronized operation. Engineered to function as a high-capacity Vial Filling and Capping Machine (with stoppering), it is the ultimate turnkey solution for pharmaceutical manufacturers requiring uncompromising sterility assurance, operational efficiency, and regulatory compliance for injectable formulations.

washing machine   The washing machine of the vial large-volume wash–dry–fill–stopper integrated line is engineered to deliver thorough and consistent cleaning for infusion vials prior to drying and filling. Vials are automatically indexed into the washing station, where multi-stage internal and external rinsing is performed using purified water and compressed air to effectively remove particulates and residues. The system ensures stable bottle handling to prevent damage while maintaining high throughput suitable for large-volume production. With precise timing control and GMP-compliant construction, the washing machine provides reliable, repeatable cleaning performance, forming a critical foundation for high-quality vial infusion manufacturing.

filling machine   The filling machine of the vial large-volume wash–dry–fill–stopper integrated line is designed for high-accuracy and stable liquid dosing in pharmaceutical production. After washing and drying, vials are precisely transferred into the filling station, where servo-controlled filling nozzles dispense consistent volumes with excellent repeatability. The system supports large-volume liquid formulations while maintaining smooth flow control to minimize foaming and product loss. Advanced bottle positioning and anti-drip nozzle design ensure clean operation and reliable batch consistency. Manufactured with GMP-compliant materials, the filling machine provides efficient, hygienic, and continuous performance within high-capacity vial infusion production lines.

A Complete, Closed-Loop Aseptic Processing Core

This integrated line represents the pinnacle of sterile manufacturing technology, eliminating manual interventions and transfer points that pose contamination risks. The process begins with a high-efficiency Vial Washing Machine that thoroughly cleans bottles with WFI (Water for Injection) and filtered air. Vials are then transferred into a Depyrogenation Tunnel where validated dry-heat cycles eliminate pyrogens. The sterile vials enter a Class A protected zone where an Aseptic Piston Filler accurately doses the liquid formulation. Finally, the line incorporates a fully automatic Stoppering Machine that precisely inserts rubber stoppers under aseptic conditions. This seamless integration creates a robust, continuous Vial Line, dramatically reducing particulate and microbial ingress while maximizing throughput.

Engineered for Sterile Manufacturing Excellence

Built to meet the most stringent global cGMP standards and the enhanced guidelines of EU Annex 1, every component is designed for sterility assurance. The line features 316L stainless steel construction, fully automatic HEPA-filtered laminar airflow protection over critical zones (filling & stoppering), and a design fully compatible with CIP/SIP systems. As a sophisticated Vial Line Machine, it provides comprehensive environmental monitoring interfaces and employs technologies such as particle monitoring ports and uni-directional air flow principles to maintain the highest grade of aseptic processing.

Core Technical Features & Operational Benefits

• Fully Integrated Continuous Process: Synchronized transfer between washing, drying, filling, and stoppering modules creates a true "linked" Vial Line, optimizing flow and minimizing bottlenecks.

• High-Capacity Aseptic Filling: Piston-based filling technology ensures volumetric accuracy (±0.5%) for large and small volumes (50ml to 1000ml+), critical for infusion solutions.

• Automatic Sterile Stoppering: The integrated stopper handling system (including bowl feeder, orienter, and insertion head) completes the container closure, functioning as the critical sealing component of this Vial Filling and Capping Machine system.

• Advanced Process Control & Data Integrity: A centralized, GMP-compliant SCADA system provides unified control, real-time monitoring of all parameters (temperature, pressure, speed), and complete electronic batch records with 21 CFR Part 11 compliance.

• Scalable & Validatable Design: The line is designed to support full validation (IQ, OQ, PQ), with clearly defined performance qualifications for each module and the integrated system.

Ideal Applications

• Large Volume Parenterals (LVPs): Saline solutions, dextrose infusions, irrigation fluids, and parenteral nutrition bags/bottles.

• Small Volume Parenterals (SVPs): Antibiotic vials, analgesic injections, and other liquid injectables in vials.

• Diagnostic & Dialysis Solutions: Sterile water and solutions for diagnostic or hemodialysis applications.

Your Partner in Building Sterile Manufacturing Capacity

We provide a complete partnership, from initial line design and factory acceptance testing (FAT) to on-site installation, commissioning, and comprehensive performance qualification (PQ) support. Our validation experts ensure this integrated Vial Line Machine meets all regulatory expectations for the production of sterile injectables.