High Speed Vial Filling and Rubber Stoppering Machine

High Speed Vial Filling and Rubber Stoppering Machine

High Speed Vial Filling and Rubber Stoppering Machine

High Speed Vial Filling with Rubber Stoppering Machine, Model LI-LVF 8 is suitable for Round Vials with maximum speed of 240 Vials per minute. The Machine can give Maximum speed of 240 Vials per minute depending on nature of Liquids, Vial Neck Size and Fill Volume. Machine construction in fully Stainless-Steel finish including machine frame structure. Machine with unique motion filling system, Filling Nozzle moves along with Vials during the Liquid Filling Process without stoppage of Vials and also with time tested vaccumetric Rubber Stoppering System for positive placement of Rubber Stopper on Vials at higher speed. Machine with built-in Turn Tables at In-feed and Out-feed with individual drives to match the speed of incoming and outgoing vials for smoother operation. All parts coming in contact with Liquids and Rubber Stoppers are made from SS 316 Materials.

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High Speed Vial Filling and Rubber Stoppering Machine

Various types of vial filling and rubber stoppering machines are available in the market. These machines are designed to fill glass vials with sterile liquid. The main components of the machine are the frame structure, conveyor, SS slat, star wheel, vibrator, and a pneumatic system.

The frame structure of the machine is made of a steel material. The Stainless Steel finish makes it easy to clean. The Stainless Steel Stat conveyor belt keeps the vials away from sticking on the conveyor. The vial is forwarded on the conveyor towards the vial liquid filling unit.

The vial liquid filling and rubber stoppering machine can be used for a wide range of liquids. The vials are filled through piston pumps. The volume can be adjusted by changing the stroke length.

The machine can be manufactured in accordance with GMP standards. The parts are made of corrosion free stainless steel SS 316. All the contact parts are removable for cleaning and sterilization.

The machine can be operated at a speed of up to 1080 rpm. It can run non-stop production cycles. It can fill vials ranging from 2ml to 250ml. It can be equipped with closed RABS and nitrogen filling.

The machine comes with a safety acrylic cover and AC Drive. It is also equipped with a Delrin Slate conveyor. It can be set to work at a certain speed, depending on the nature of the liquid.

Vial Filling Machine History

Stainless steel slat conveyors, bottom-close nozzles, and palletizers are some of the components of an automatic vial filling machine. They help to provide a smooth flow of product to the end user, and also to increase the productivity of the operation.

The process of filling pharmaceutical products requires them to be free of contaminants and sterile. These machines are designed to provide the best safety for the production of liquid products.

These filling machines are available in a variety of models, which can be used for different applications. They can handle products that require reliable cold filling, as well as viscous and thin products. They may also have the option of integrating a freeze drying, sterilization, or external cleaning process.

These machines can be used to fill jars, bottles, and other containers of a variety of shapes and sizes. The rate of filling can be adjusted according to the needs of the end user.

These machines may have multiple filling heads that can help to increase the speed of the operation. These may include up to twelve heads, which will increase productivity.

These machines are built in modern manufacturing facilities, and they are highly suited for pharmaceutical application. The high-end sterile filters ensure the highest quality of the process.

The machine also has a safety guard that protects the motor and the conveyor gearbox. A servo control system provides precision and accuracy, and the machine is capable of filling vials to +/- 1 percent.

Vial Filling Machine Working Principle

Usually, there are three basic components in a vial filling machine. These are the filling head, the hopper and the conveyor belt.

The hopper is designed to hold the bottles. They can be glass or plastic. The hopper is ideal for liquids that are viscous or granular.

The filling head is composed of different spouts that are used to fill the vials. The filling head accurately fills the vials. There are special design vial filling machines that are semi-automatic or automatic. They are often preferred by manufacturers.

The conveyor is used to move the bottles from the hopper to the filling station. The number of filling heads is determined by the number of bottles. When the number of filling heads matches the number of bottles, the motor stops. The empty bottle is intercepted by the outlet stop rod.

The void star wheel discard maneuver ensures that no non-compliant vials are included. This reduces contamination and speeds up the production process.

A rotary/ball valve control system helps solve pressure problems caused by a high position. It can be used for thick or high viscous products.

Vial filling machines can be used in a number of industries. They are widely used in the pharmaceutical industry. They are also useful in the food and beverage, cosmetics and specialty chemical industries.

When you are purchasing a vial filling machine, you should ensure that it is made of stainless steel. This material is known for its resistance to corrosion. You should also ensure that the electrical components are D Group standards. This is important for safety.

Special Features of High Speed Vial Filling and Rubber Stoppering Machine:

  • No Vial - No Fill System, No Vial - Machine Stop System
  • No Stopper - Machine Stop System
  • Synchronized movement of Vial and Filling Nozzle, no stoppage of vial during filling operation
  • Vacuumetric Rubber Stoppering System.
  • All contact parts made of SS 316 material with easy removal system for Auto-Claving/Sterilization/Cleaning
  • Machine construction in SS 304 material
  • Diving Nozzle for Foam free filling
  • Very High Fill Accuracy
  • Automatic Infeed and Exit of Vials
  • Minimum Change Over time
  • Built-in A.C. Variable Freq. Drive System

Technical Specification of High Speed Vial Filling and Rubber Stoppering Machine:

Model No.: LI-LVF 8
Production Output Max. 240 per min
Vial Diameter 15mm to 50mm*
Vial Height 75mm Maximum*
Rubber Stopper Diameter 13mm and 20mm Dry or Wet Grey Butyl
Fill Range 1ml to 30ml with help of Change Parts / Syringes
Accuracy +/- 1% Depending on Liquid with Single Dose
Electrical 220 VAC Single Phase Power Supply (50 Hz)
Power 3.0 H.P.
Syringe Fill Range 0.1ml to 1ml, 1ml to 5ml, 2ml to 10ml and 10ml to 30m
Conveyor Height 800 - 850 mm
Overall Dimensions 2440 mm (L) x 1100 mm (W) x 1500 mm (H)
* Specification can be changed as per customers’ requirements

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Faq's

The LI-LVF 8 is a high-speed vial filling and rubber stoppering machine suitable for round vials with a maximum speed of 240 vials per minute. Lodha PharmaIt is Lodha's most advanced and fastest vial filling machine — purpose-engineered for large-scale pharmaceutical injectable lines where maximum throughput, sterility assurance, and fill accuracy are simultaneously required.

The single most important difference is the unique motion filling system. The filling nozzle moves along with vials during the liquid filling process without stoppage of vials Lodha Pharma — meaning vials never pause during filling. The LI-LVF 4 uses intermittent motion — vials stop briefly at the filling station. This continuous nozzle-follows-vial motion is what enables the LI-LVF 8 to achieve 240 vials per minute — double the LI-LVF 4's 120 vials per minute — without any compromise in fill accuracy or stopper placement quality.

In the unique motion system, the vial and filling nozzle move in synchronized movement — there is no stoppage of vial during filling operation. Lodha Pharma The nozzle travels alongside the vial throughout the fill cycle, maintaining perfect alignment with the vial neck at all times. This eliminates the mechanical start-stop stress on vials at high speed — reducing vial breakage risk, preventing liquid splashback, and ensuring consistent fill volumes across every single vial in the production run at 240 VPM.

The machine is suitable for round vials, with speed depending on nature of liquids, vial neck size, and fill volume. Lodha Pharma It handles round glass vials from 2 ml to 100 ml — covering the complete standard pharmaceutical injectable vial range used across liquid injectables, vaccines, biologics, ophthalmic solutions, and premium cosmetic ampoule formats.

At 240 vials per minute, the LI-LVF 8 produces approximately 14,400 vials per hour. In a standard 8-hour production shift, this translates to approximately 115,200 vials — depending on vial format and fill volume. This per-shift capacity makes it the only vial filling machine in Lodha's range capable of meeting the highest-volume pharmaceutical injectable commercial demand in a single machine.

Yes — without exception. Machine construction is in fully stainless steel finish including machine frame structure. Lodha Pharma All parts coming in contact with liquids and rubber stoppers are made from SS 316 materials Lodha Pharma — the pharmacopoeially mandated standard for injectable manufacturing equipment. All contact parts are made of SS 316 material with easy removal system for autoclaving, sterilization, and cleaning Lodha Pharma — meeting Schedule M (Revised), WHO-GMP, and EU GMP Annex 1 requirements for sterile injectable manufacturing.

It is designed for all large-volume sterile liquid injectable production — antibiotic injectables (ceftriaxone, meropenem, piperacillin-tazobactam), antifungals, biologics, vaccines, oncology/cytotoxic injectables, ophthalmic sterile solutions, multi-dose vials, single-dose injectables, and any sterile liquid formulation where the production scale demands the maximum available filling speed.

The "No Vial – No Fill" system automatically stops filling when no vial is present Lodha Pharma — preventing liquid spillage across the high-speed conveyor, product wastage, and sterile zone contamination. At 240 VPM, even a two-second uncontrolled fill gap wastes eight vials' worth of product — making this sensor system a meaningful cost and compliance protection feature at high-speed scale.

If vial feed is interrupted on the high-speed line for any reason, the machine stops completely and automatically — protecting sterile zone integrity, preventing uncontrolled filling in the absence of vials, and maintaining batch documentation continuity. At 240 VPM, automatic machine stop on vial absence is not just a quality feature — it is a critical sterility assurance control.

The "No Stopper – Machine Stop" system stops the machine when stopper supply is interrupted Lodha Pharma — ensuring no filled vial exits the machine without a rubber stopper. At 240 VPM, even a momentary stopper supply gap could result in dozens of unsealed filled vials entering your downstream line before detection — representing a sterility breach and batch rejection risk that this automatic stop completely eliminates.

The machine features a time-tested vacuumetric rubber stoppering system for positive placement of rubber stoppers on vials at higher speed. Lodha Pharma At 240 VPM, standard gravity-assisted or mechanical press stoppering cannot reliably achieve consistent stopper placement — stoppers may skip, misalign, or seat incompletely at high speed. The vacuumetric system uses vacuum-assisted positive placement — the stopper is actively pulled into correct position on the vial neck before pressing — delivering confirmed, consistent, deep-seated stopper placement at the machine's full 240 VPM operating speed.

Yes. The machine can be used to fill sterile liquids in open RABS (Restricted Access Barrier Systems) and can also be equipped with closed RABS and Isolator systems Lodha Pharma — providing the highest level of sterility assurance for biological products, vaccines, cell and gene therapies, and other highly sensitive injectable formulations that require Grade A environmental control throughout the filling and stoppering process.

Yes. The machine has the option of nitrogen flushing before and after the filling operation Lodha Pharma — essential for oxygen-sensitive injectable formulations including antibiotics, biologics, and oncology products where even trace oxygen exposure during filling causes API degradation, potency loss, or colour change. The SS 316 nozzle design accommodates pre-fill and post-fill N₂ gassing stations as part of the synchronized filling zone.

Yes. All contact parts are made of SS 316 material with easy removal system for autoclaving, sterilization, and cleaning Lodha Pharma — allowing complete contact part sterilization between production batches as mandated by Schedule M, WHO-GMP, and EU GMP Annex 1 for sterile injectable manufacturing environments.

Yes. The machine's synchronized continuous motion filling system, consistent eight-head volumetric operation, documented SS 316 contact part specifications, triple safety sensor systems, and AC variable frequency drive parameters provide the process consistency and documented control data required for IQ/OQ/PQ validation — supporting regulatory submissions for CDSCO, WHO-GMP, USFDA, and EU GMP-regulated markets.

At 240 VPM — approximately 115,200 vials per 8-hour shift — the LI-LVF 8 is the machine that makes large-scale government pharmaceutical tender fulfillment commercially viable. Manufacturers supplying national essential medicines lists, hospital formularies, government procurement agencies (like HLL Lifecare or state medical services corporations), and international procurement bodies (UNICEF, GAVI, MSF) need this level of filling capacity to meet contracted volumes on schedule without overtime production or multiple machine investment.

Yes — for India's largest Ayurvedic manufacturers producing high-volume sterile or semi-sterile vial preparations at commercial scale. Ayurvedic parenteral preparations classified under Schedule T, large-volume Ayurvedic ophthalmic preparations for institutional supply, and Ayurvedic nasal preparations for national distribution all benefit from the LI-LVF 8's 240 VPM capacity — enabling high-volume Ayurvedic vial production that matches commercial demand without production bottlenecks.

Yes. Ayurvedic ophthalmic preparations — herbal eye drops, Triphala eye solutions, medicated ophthalmic liquids — are sterile, low-volume fills in small glass vials (5 ml to 15 ml) where production scale matters for large institutional supply. The LI-LVF 8's continuous motion system handles small-format vials at maximum speed with the SS 316 contact part construction and sterile filling environment compatibility that AYUSH GMP and state drug authority regulations require for ophthalmic preparations.

Yes. The LI-LVF 8's full SS construction, SS 316 contact parts, vacuumetric stoppering, RABS/Isolator compatibility, nitrogen gassing option, autoclavable components, triple safety systems, and Lodha's ISO 9001:2015 manufacturing credentials provide the complete equipment compliance foundation that WHO pre-qualification technical assessors review — supporting dossier submissions for WHO-GMP, EU GMP, and international export market regulatory approvals for Ayurvedic sterile products.

Contact Lodha International LLP with your vial size range, fill volumes, liquid type, required output speed, regulatory framework, and special requirements (nitrogen gassing, RABS/Isolator, lyophilization compatibility) — and their technical team will configure the right specification for your high-speed injectable production line.
📞 +91 9687731331 | +91 9687631331 | +91 9537131331
📧 info@lodhapharma.com
🌐 www.lodhapharma.com
15,500+ machines installed across 50+ countries since 1995 — India's most trusted high-speed pharmaceutical injectable packaging machinery manufacturer from Ahmedabad, Gujarat.

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