Vial Packaging Line

"Follow-the-Vial" Integrated Aseptic Line: Complete System for 32-Head Washing & 16-Head Precision Filling

Engineer a seamless, closed-loop aseptic process with our advanced "Follow-the-Vial" Integrated Production Line, a sophisticated vial packaging line specifically configured for critical injectable and sterile liquid manufacturing. This turnkey solution unites a High-Speed 32-Head Vial Washer with a Precision 16-Head Tracking Filler to create a complete, validated vial filling line from depyrogenation to dose delivery. Designed for high-throughput pharmaceutical and biotech production, this integrated system minimizes human intervention and particulate contamination, providing a robust, automated foundation for the sterile filling and sealing of vials. The innovative "tracking" filling technology ensures unparalleled accuracy and gentleness for sensitive biologics, vaccines, and ophthalmics.

capping part   The capping part of the system features a high-stability mechanism designed specifically for small pharmaceutical vials following the 16-head tracking filling section. Vials enter the capping zone in a continuous flow, where the rotary or tracking-style capping heads position and secure each cap with precise torque control. The system maintains synchronized motion with the moving vials, ensuring smooth, vibration-free sealing without bottle damage. Its servo-driven capping heads, automatic cap feeding, and real-time torque monitoring guarantee uniform tightness, preventing leakage and ensuring compliance with GMP sealing standards. This capping module delivers reliable, high-speed performance essential for sterile vial production.

washing part   The washing part utilizes a 32-head vial washing machine engineered for pharmaceutical-grade cleanliness and consistent pre-treatment. Each vial is gripped and indexed through a series of high-efficiency internal and external washing stations, where purified water and compressed air are applied in alternating cycles to remove particles, residues, and potential contaminants. The multi-head design ensures uniform cleaning performance while supporting high-speed throughput required for continuous production. With precise timing control, stable bottle positioning, and compatibility with various vial sizes, this washing module delivers reliable, GMP-compliant preparation before the vials enter the filling and capping stages.

A Complete, Two-Stage Aseptic Processing Core

This system is engineered as a unified production cell, eliminating transfer bottlenecks and exposure risks. The process begins with the high-capacity 32-head rotary washer, which thoroughly cleans and depyrogenates glass vials using validated cycles of WFI (Water for Injection) and filtered compressed air. The vials are then transferred in a protected manner directly into the critical zone of the 16-head tracking filler. Here, the filler's nozzles descend and move in sync with each individual vial during the dosing cycle—a motion that prevents splashing, reduces foam, and guarantees fill volume accuracy within ±0.5%. This integrated design forms the core of a reliable vial filling line, ready for integration with downstream stoppering and capping machines to complete the filling and sealing of vials.

Pharmaceutical-Grade Design for Maximum Product Protection

Constructed to meet stringent global cGMP standards and the principles of Annex 1, every component is designed for cleanability and sterility assurance. The system features 316L stainless steel construction, electropolished surfaces, and a hygienic design fully compatible with CIP/SIP. The washer employs precision needle manifolds for internal vial cleaning, while the filler utilizes peristaltic pump technology with single-use fluid paths, creating a closed system that eliminates cross-contamination. This makes the entire vial packaging line ideal for potent compounds, multi-product facilities, and sterile manufacturing where product integrity is paramount.

Core Technical Features & Operational Benefits

• High-Throughput Washing & Precision Filling: The 32-head washer ensures a consistent supply of clean, dry, and depyrogenated vials to the 16-head tracking filler, optimizing line balance and overall equipment effectiveness (OEE).

• "Follow-the-Vial" Filling Technology: Ensures gentle, precise fills (1mL - 100mL) for shear-sensitive products like proteins, mAbs, and cell therapies, minimizing waste and maximizing yield.

• Integrated, Protected Transfer: A closed or laminar-flow protected transfer between modules minimizes the risk of airborne particulate contamination before filling.

• Regulatory Compliance Ready: The centralized control system offers full data integrity with 21 CFR Part 11-compliant software, electronic batch records, and complete audit trails for both washing and filling cycles.

• Scalable & Modular Design: This core vial filling line is designed for future expansion, allowing for seamless integration with automatic stoppering, capping, and sealing stations to achieve complete filling and sealing of vials.

Ideal Applications for Critical Liquid Formats

• Sterile Injectables: Vaccines, antibiotics, biologics, and high-potency oncology drugs.

• Ophthalmic Solutions: Prescription eye drops, lubricants, and surgical irrigations.

• Diagnostic & Laboratory Reagents: Sterile buffers, calibrators, and enzyme solutions.

• Advanced Therapy Medicinal Products (ATMPs): Cell and gene therapy vectors and associated media.

Your Partner in Sterile Manufacturing Excellence

We deliver a complete qualification package and partnership. Our support extends from factory acceptance testing (FAT) and site acceptance testing (SAT) to assistance with installation qualification (IQ), operational qualification (OQ), and performance qualification (PQ). We ensure this vial packaging line is fully validated and optimized for your specific product and throughput requirements.