Automatic Vial Filling and Rubber Stoppering Machine

The Automatic Vial Filling and Rubber Stoppering Machine consist of a main structure covered with SS cabinet safety acrylic cover

Automatic Vial Filling and Rubber Stoppering Machine

Automatic Vial Filling and Rubber Stoppering Machine

The Automatic Vial Filling and Rubber Stoppering Machine from USA Pack Machines LLC is a state-of-the-art solution designed to streamline sterile pharmaceutical packaging with maximum precision and efficiency. Engineered for high-performance vial processing, this machine combines cutting-edge technology with robust construction to meet the most demanding industry standards.

Precision Filling with Reliability
At the heart of this system lies the peristaltic pump filling mechanism, which ensures accurate, consistent, and contamination-free filling of liquid medicines. This advanced design reduces product wastage while safeguarding sterility, making it ideal for pharmaceuticals that require strict quality assurance. The machine handles a wide range of fill volumes, ensuring flexibility across different product lines.

Integrated Rubber Stoppering System
Following the filling process, the system incorporates an automatic rubber stoppering unit. A vibrator bowl and chute efficiently orient and feed stoppers, while the pneumatic components ensure precise placement on each vial. This seamless integration not only accelerates production but also guarantees secure sealing, preserving product integrity throughout its shelf life.

Robust Structure and Safety Features
The equipment is built on a stainless-steel main structure with a safety acrylic cover, ensuring durability while maintaining a clean and sterile environment. The inclusion of a laminar airflow system provides an additional layer of protection, minimizing contamination risks during critical operations. The Delrin slate conveyor ensures smooth vial movement from in-feed to outfeed turntables, optimizing the entire process flow.

Intelligent Automation and Control
Equipped with a PLC-based control system and user-friendly HMI, operators can easily monitor performance, adjust parameters, and maintain consistent production quality. The electrical panel, AC drive, and integrated sensors work together to deliver reliable and efficient performance with minimal downtime.

A Smarter Choice for Pharma Manufacturing
By combining precision filling, sterile stoppering, and advanced automation, the Automatic Vial Filling and Rubber Stoppering Machine from USA Pack Machines LLC delivers unmatched efficiency for pharmaceutical manufacturers. Designed for compliance with global standards, it is the ideal choice for companies aiming to enhance productivity while maintaining the highest levels of product safety and quality.

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# Model Output Speed
1 UPML-PRE-VFB 30 to 400 Vials/Minute (Depend upon nature of liquid & size of vials)
  • The machine is made compact & versatile as per GMP norms.
  • The structure is made out of MS cladding with SS 304.
  • Rigid vibration-free construction for trouble-free performance.
  • The contact parts such as filling nozzle, bung disc are made of SS316 L.
  • The Pharma grade silicon tubes are used for filling & CIP/SIP.
  • Easy to clean the base of the machine.
  • There is a special feature called PRIME which is useful to suck the filling material from storage tank to nozzle end very quickly. Moreover, this facility is useful to clean the filling line (silicon tubes) as well as filling peristaltic pump in both directions.
  • The machine has a facility of using PRIME function for all the peristaltic pumps together or individual peristaltic pumps also.
  • The process of filling is done by specially designed filling peristaltic pump which can serve the purpose of CIP & SIP.
  • Individual pumps can be adjusted & calibrated for the desired volume – by use of easy to operate PLC.
  • Oil-based material can also be run easily without dripping because of specially designed peristaltic pump with the facility of suck back.
  • Each filling head can work independently & hence the machine works continuously without sacrificing major production.
  • No change parts are required for different size of vials as well as different filling volume.
  • There is a very less product change over time due to very less usage of mechanical parts such as syringe set, Teflon seal, gear & chain etc.
  • Easy to operate PLC for any kind of volume adjustment or speed adjustment.
  • Synchronized filling system for smooth filling purpose.
  • Specially designed bung oriental bowl & discharge chute with in-built vibrator. The bung oriental bowl & chute are Teflon coated for use of wet bungs.
  • Bungs are held in the specially designed vacuum bung hold disc & the same disc discharge the bung uniformly on the vial. The bung pressing roller presses the bungs uniformly.
  • The same Rubber bunging machine assembly can also be utilized for half stoppering.
  • For different heights of vials, the whole assembly can be moved upwards & downwards.
  • Alarm alerts through PLC for “No Vial, Machine Stop” & No Vial, No Bung”.
  • Production counter is given with password protection for daily track report and planning for the same.
  • The faults can be detected on the PLC touch screen HMI and can be attended easily for the same.
  • The machine is supplied with isolated power supply to avoid the adverse effect of electric supply.
  • The output speed can be appeared on HMI screen and adjust the same as per appropriate requirements.
  • Very less mechanical adjustment required due to the special design.
  • User-friendly and very less maintenance required.
  • Nitrogen facility (Pre or Post) can be provided as an (OPTIONAL).
  • Unique design of rolling conveyor.
  • Easy loading of vials to in-feed turntable – by loading tray.
  • For smaller vials, the speed of turntable can be set individually.
  • Filling machine with tray to spillage and connection of drain.
  • Conveyor of Filling and cap sealing machine covered with acrylic cover.
  • Most reliable & proven mechanical components such as FESTO make pneumatics & CE certified electrical/electronic such as Bonfiglioli make AC motor, Allen Bradley make drives, PLC & HMI Touch screen, Sensors, MCB’s, relay etc.
Vials Diameter 25 mm to 55 mm
Rubber Bung Size 13 mm, 20 mm & 32 mm
Output Speed 30 to 400 Vials/Minute
(Depend upon nature of liquid & size of vials)
Filling Volume 2 ml to 30 ml
Filling Head 4 / 6 / 8 Heads
Working Height 875 ± 50 mm Adjustable
Power Consumption 2.5 KW
Power Supply 3 Phase + Neutral + Earthing/ 415 V AC/ 50 Hz
Air Supply 4 to 6 Kg/Cm²
Net Weight 650 Kg Approx.
Dimensions 2700mm (L) x 1500mm (W)x 2000 mm(H) Approx.

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