Aseptic Vial Filling System

Q: How does the machine ensure filling accuracy and consistency?

The VialFill system is equipped with individual servo filling pumps, enabling more fill time and a gentle filling action with filling accuracy at ±1%.

Q: What flexibility does the system offer for different vial sizes and batch change-overs — critical in a multiproduct facility?

Filling range is from 0.1ml up to 100ml and supports vials from 2R to 100R size. VialFill is full-servo driven with rapid changeover via recipe and minimum change part for quick product changeover.

Q: How is aseptic integrity maintained, and how does the machine align with regulatory requirements for injectables?

The machine supports a barrier system design (Laminar Air Flow, open RABs or isolator) suitable for Grade A / ISO Class 5 environments and VHP compatible. VialFill complies with FDA 21 CFR Part 11.

Q: What features facilitate production monitoring, data integration and validation?

VialFill includes a 15″ IPC HMI with recipe management, non-editable audit trail, 3-level user management, OPC UA communication port for MES/ERP integration, and optional cloud-based real-time OEE monitoring. Documentation compliant with FDA 21 CFR Part 11.

Q: How does the machine minimise downtime and maximise throughput?

The specification states production speeds up to 200 vials per minute. Auto rejection without machine stop, bottle-topple detection and vibrator sorting bowl reduce stoppages and product rejects. The servo-driven rapid changeover design also reduces downtime.

Streamline your vial filling process with VialFill, our high-performance Vial Aseptic Liquid Filling Line!

Engineered to deliver unmatched precision, VialFill combines advanced Filling, Stoppering, and Capping modules, achieving production speeds of up to 200 vials per minute.

Seamlessly integrate with your Washing and Depyrogenation Tunnel for an uninterrupted, fully aseptic processing flow, ensuring the highest standards for injectable liquids.

Maximize efficiency and reliability in every batch with VialFill – your trusted partner in aseptic filling excellence!

Get Quote

Features

Performance – Walking beam Nozzle for one time filling to achieve more filling time for gentle filling, Individual Servo Filling pump for highest accuracy.
Product Safety – Multiple detection and inspection available, 100% tare in tare out, under torque etc.
Conversion – Full Servo Driven with rapid changeover via recipe and minimum change part.
Compliance – 15” IPC HMI comply to FDA 21 CFR Part 11 and European safety CE Marked.
Digitalization – Ready with OPCUA communication port for MES and ERP , Cloud base real-time OEE Monitoring.
Barrier System – LAF , Open RABs or Isolator design to GMP Annex 1.
Documentation – Full Validation document DQ(RA, FSDS, HDS, SDS, CSV) , IQ, OQ.
Barrier System – Grade A or ISO Class 5 environment, Suitable for Laminar Flow, Open RABs or Isolator, VHP compatible

Software & Digitalization

15” IPC intuitive design HMI
Comply to FDA 21 CFR Part 11
Electronic Batch Record
Non-editable Audit Trial
3 level user management
Recipes
OEE dashboard visualization
OPCUA communication ready
Remote Access troubleshooting (optional)
Cloud base Real-time OEE monitoring (optional)

Machine Specification

Model	HFS 60V	HFS 120V	HFS 180V	HFS 250V
Output (upm)	up to 50	up to 100	up to 150	up to 200
Filling Accuracy	+/-1%
Filling Range	0.1ml – 100ml
Suitable Packaging	Vial Glass 2R – 100R Rubber Stopper Aluminium Cap
Electricity	3KW @ 380-415VAC	4KW @ 380-415VAC	5KW @ 380-415VAC	6KW @ 380-415VAC
Air Supply	50LPM @ 6bar	50LPM @ 6bar	60LPM @ 6bar	60LPM @ 6bar
Dimension (mm)	L: 1560 W: 1860 H: 1870	L: 1800 W: 2050 H: 1870	L: 2250 W: 1050 H: 2280	L: 3550 W: 1050 H: 2280

Monoblock Design

Starwheel Design

Vial Loading With Bottle Topple Detection

Filling Range From 0.1ml -100ml

Auto Rejection Without Machine Stop

Smooth Sorting via SUS 316L German Vibrator Sorting Bowl

Filling Accuracy +/ - 1% Or Better

Contact Parts Are FDA Approved Material And Autoclavable.

Patented Elevator Cap Sorter Without Vibration Noise < 70db

Machine Layout

Frequently Asked Questions (FAQs)

How does the machine ensure filling accuracy and consistency

The VialFill system is equipped with individual servo filling pumps, enabling more fill time and a gentle filling action with filling accuracy at ±1%.

What flexibility does the system offer for different vial sizes and batch change-overs — critical in a multiproduct facility?

Filling range is from 0.1ml up to 100ml and supports vials from 2R to 100R size. VialFill is “full-servo driven with rapid changeover via recipe and minimum change part” for quick product changeover.

How is aseptic integrity maintained, and how does the machine align with regulatory requirements for injectables?

The machine supports a barrier system design (Laminar Air Flow, open RABs or isolator) suitable for Grade A / ISO Class 5 environments and VHP compatible. VialFill complies to FDA 21 CFR Part 11.

What features facilitate production monitoring, data integration and validation

VialFill includes a 15″ IPC HMI with recipe management, non-editable audit trail, 3-level user management, OPC UA communication port for MES/ERP integration, and optional cloud-based real-time OEE monitoring. Documentation compliant with FDA 21 CFR Part 11.

How does the machine minimise downtime and maximise throughput

The specification states production speeds up to 200 vials per minute. Auto rejection without machine stop, bottle-topple detection and vibrator sorting bowl reduce stoppages and product rejects. The conversion design (servo-driven, rapid changeover) also reduces downtime.