Automatic Injectable Liquid Vial Filling And Stoppering Machine

Automatic Injectable Liquid Vial Filling & Stoppering Machine

Advanced Monoblock Engineering: Sterile Integrity by Design

In the rigorous landscape of sterile injectable manufacturing, maintaining absolute sterility, uncompromised safety, and pinpoint dosing accuracy is non-negotiable. The Harsiddh Automatic Injectable Liquid Vial Filling & Stoppering Machine (HLVF Series) stands at the forefront of aseptic processing technology.

This state-of-the-art system expertly unifies two critical manufacturing stages—ultra-precise liquid volumetric filling and immediate rubber stoppering—into a single, compact, and highly synchronized operational footprint. By eliminating extensive conveyor tracks between separate modules, the HLVF monoblock architecture minimizes the critical window that an open container remains exposed to ambient air. The streamlined geometry integrates seamlessly under Laminar Air Flow (LAF) workbenches or Restricted Access Barrier Systems (RABS), providing an uninterrupted stream of sterile air over your product during its most vulnerable phase.

Strategic Benefits & Performance Highlights

• Micro-Precision Volumetric Dosing: Achieves an exceptional filling accuracy of ±1% utilizing premium-grade, highly calibrated volumetric syringes, keeping high-value product giveaway to an absolute minimum.
• Smart Waste-Prevention Array: Integrated “No Vial – No Fill – No Stopper” optical and proximity logic immediately halts individual stations if a conveyor gap is detected, preventing costly liquid spillage and machinery contamination.
• Bottom-Up Diving Nozzles: Synchronized cam-driven diving nozzles execute a bottom-up filling stroke, effectively eliminating fluid splashing, micro-foaming, and exterior container contamination.
• Oxidation Protection: Integrated pre-filling Nitrogen (N₂) gassing loops displace ambient oxygen, dramatically extending the shelf-life and chemical stability of sensitive therapeutic proteins and vaccines.
• Gentle Mechanical Indexing: Custom-engineered star wheel positioning tracks handle delicate molded or tubular glass vials (2ml to 100ml) flawlessly, eliminating glass-on-glass friction and high-speed tipping.

The Synchronized Aseptic Processing Cycle

Operating on a continuous, linear, left-to-right online workflow, the HLVF Series moves vials through five precisely timed phases:

[Infeed Unscrambler] ➔ [1. N₂ Oxygen Purge] ➔ [2. Precision Volumetric Fill] ➔ [3. Vibratory Rubber Stoppering] ➔ [4. Outfeed Scrambler Tray]

1. Automated Vial Infeed: Raw, sterilized vials from a depyrogenation tunnel load onto a heavy-duty in-feed turn table (unscrambler) that smoothly aligns and channels them onto a variable-speed stainless steel conveyor.
2. Pre-Filling Nitrogen Gassing: Diving gas needles purge the vial cavity with an inert nitrogen blanket, preserving the structural efficacy of oxidation-sensitive APIs.
3. High-Precision Liquid Dosing: Volumetric syringes cleanly dispense liquid via independent mechanical circuits. The modular layout allows configuration from 2 up to 8 heads to match your facility’s target throughput.
4. Continuous Rubber Stoppering: Stoppers sort continuously inside a low-noise vibratory bowl, travel down a precisely machined chute, and are pressed firmly onto the vial necks via a pick-and-place vacuum system, sealing the fluid instantly.
5. Outfeed Batch Collection: Hermetically stoppered vials exit the monoblock unit and transfer onto the out-feed turn table (scrambler), organized and ready for aluminum cap crimping and serialization.

cGMP Compliance & Intelligent Controls

Sanitary, Clean-in-Place Architecture

Every component touching your fluid formulation—including syringes, rotary valves, delivery manifolds, and diving needles—is manufactured from premium AISI 316L stainless steel. Non-contact structures utilize AISI 304, featuring ultra-smooth, polished geometries designed for rapid Cleaning-in-Place (CIP) and Sterilization-in-Place (SIP) protocols.

Advanced PLC Touchscreen Automation

The entire processing line is managed through an intuitive, user-friendly Touchscreen HMI paired with a high-performance PLC. Cleanroom operators can easily calibrate filling volumes on the fly, track live batch counts, adjust conveyor speeds, and monitor real-time diagnostic alerts from a centralized location.

Technical Specification

Specification	HLVF – 60 (2 Head)	HLVF – 100 (4 Head)	HLVF – 150 (6 Head)
Output / Minute	30 to 50 Vials	50 to 100 Vials	100 to 150 Vials
Vial Size Range	2ml to 100ml	2ml to 100ml	2ml to 100ml
Filling Accuracy	± 1%	± 1%	± 1%
Filling Type	Volumetric Piston Pump	Volumetric Piston Pump	Volumetric Piston Pump
Stopper Sizes	13, 20, 28, 32mm	13, 20, 28, 32mm	13, 20, 28, 32mm
Contact Parts	SS 316L	SS 316L	SS 316L
Power Requirements	1.0 H.P. Main	1.0 H.P. Main	1.0 H.P. Main

Why Choose Harsiddh?

Investing in the Harsiddh HLVF Series Automatic Injectable Liquid Vial Filling & Stoppering Machine means partnering with a legacy of engineering excellence. We understand that in sterile manufacturing, a fraction of a millimeter or a single drop can make a monumental difference.

Our machines undergo rigorous Quality Assurance (QA) inspections and Factory Acceptance Testing (FAT) before deployment, ensuring seamless installation, quick validation, and minimal ramp-up time at your facility. Elevate your pharmaceutical production line with unparalleled accuracy, scalable speeds, and ironclad sterility compliance.

Contact the Harsiddh engineering team today to request a custom quote, technical consultation, or a virtual equipment demonstration.