AIPAK ENGINEERING Vial Filling Line
AIPAK Engineering vial filling line is a complete linked system for glass vials, integrating ultrasonic washing, depyrogenation tunnel sterilization, filling, and aluminum-cap crimping into one continuous line. Depending on the product, the same platform is configured for two routes — liquid injectable (water-for-injection) filling and sterile powder filling — processing vials from 2 ml up to 30 ml under GMP conditions.
Both routes run the full sequence — ultrasonic non-contact washing, hot-air tunnel depyrogenation (endotoxin reduction ≥ 3 log), precision filling, and crimp sealing — under Siemens PLC control, with Class 100 laminar flow over the sterile zone, 316L product-contact surfaces, and 21 CFR Part 11 / GAMP5 data integrity.
AIPAK Engineering delivers the vial line as a linked turnkey system under one contract, with IQ/OQ/PQ validation protocols, FAT/SAT, and GMP & CE certificates.
Vial Filling Line
Liquid Vial (Water-for-Injection) Filling Line
For liquid injectables in glass vials. The line fills with 12 ceramic pumps and servo-tracked needles, performs vacuum semi-stoppering, and crimp-seals aluminum-plastic caps. Up to 300 vials/min (10 ml), filling accuracy ≤ ±1%, stoppering & capping pass rate ≥ 99.9%.
12 ceramic pumps, filling accuracy ≤ ±1%
Servo XY-tracking fill, liquid-level-following needles
Up to 300 vials/min (10 ml), breakage ≤ 0.01%
Automatic Lyophilized Powder for Injection Vial Filling Line
AIPAK ENGINEERING lyophilized powder for injection vial filling line is a specialized pharmaceutical manufacturing system designed to accurately dose sterile powder formulations into vials and prepare them for lyophilization (freeze-drying). The process typically involves vial washing, sterilizing, precise powder dosing using auger or vacuum-based systems, partial stoppering to allow for freeze-drying, lyophilization to remove moisture while preserving product stability, and final capping to ensure a secure seal.
High degree of automation
Few operators required
No-bottle-no-filling, no bottle no stoppering, no bottle no capping and squeeze stop functions
Sterile Powder Vial Filling Line (Magnetic-Levitation, 100% In-Process Weighing)
For sterile powder injectables (e.g. antibiotic / cephalosporin powder) in glass vials. Vials ride on magnetic-levitation trolleys through weigh–fill–weigh stations: empty vials are weighed (station A), screw-filled by servo-driven dispensing screws, then weighed again (station B) for 100% in-process weight check (IPC). Out-of-spec vials are automatically rejected; qualified vials proceed to nitrogen filling, stoppering and capping.
Magnetic-levitation positioning + 100% in-process weighing (IPC)
Servo screw filling 0.5–5.0 g, fill difference ±4%, weighing error ≤ ±5–8 mg
Up to 400 vials/min (10 ml), nitrogen filling (O₂ ≤ 3%), no-vial-no-fill
Vial Filling Line Applications
AIPAK ENGINEERING Vial Filling Line is a fully automated, high-precision solution designed to meet the demanding needs of modern pharmaceutical manufacturing. It is widely used in:
Injectable Pharmaceuticals
Biopharmaceutical & Sensitive biologics
Cosmetics & Nutraceuticals
Chemical & Laboratory Solutions
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Vial Filling Machine FAQ
Q1: What types of vials can this filling line handle?
AIPAK ENGINEERING Vial Filling Line is compatible with a wide range of vial types, including glass and plastic vials, with volumes from 2 ml to 50 ml. Custom sizes can also be accommodated.
Q2: What is the production capacity of the Vial Filling Line?
Depending on the configuration, AIPAK ENGINEERING vial filling line can achieve production speeds of up to 6,000 vials per hour, ensuring high-efficiency operation for large-scale pharmaceutical production.
Q3: How is sterility maintained during the filling process?
Sterility is ensured through a combination of vertical ultrasonic bottle washing, hot air sterilization tunnel, and a fully enclosed filling and capping system, preventing contamination throughout the process.
Q4: Can the filling and capping parameters be adjusted?
Yes, the linear filling machine allows precise adjustment of liquid volume, and the vial capping machine provides adjustable rotation speed and number of turns to ensure consistent crimping quality.
Q5: How does the system prevent bottle tipping or breakage?
AIPAK ENGINEERING Vial Filling Line uses spiral bottle feeding, stable star wheel positioning, and anti-gap devices on the capping machine, minimizing the risk of tipping, cracking, or breakage during high-speed operation.
Q6: What type of pumps are used for liquid transfer?
AIPAK ENGINEERING vial filling line can be equipped with peristaltic pumps for sterile, contamination-free filling, or ceramic piston pumps for high-precision, chemically resistant applications.
Q7: Is the system easy to clean and maintain?
Yes, the design emphasizes ease of maintenance, with minimal valves and seals, quick tubing replacement for peristaltic pumps, and CNC-machined capping assemblies for consistent performance.
Q8: Can the line handle different liquid types?
The system can process various liquids, including aqueous solutions, suspensions, corrosive liquids, oxygen-sensitive formulations, and viscous materials, depending on the selected pump and configuration.
Q9: Does the vial filling line comply with international standards?
Absolutely. AIPAK ENGINEERING Vial Filling Line is designed to meet GMP, ISO, and FDA requirements, ensuring pharmaceutical-grade quality and regulatory compliance.
Q10: Can the line be customized for specific production needs?
Yes, the modular design allows customization of production speed, vial size, filling volume, and additional features like automated stopper/cap inspection, making it suitable for diverse manufacturing requirements.
