High-Precision, Compact Monoblock Solution for Small Volume Pharmaceutical, Biotech, and Diagnostic Packaging

In specialized pharmaceutical manufacturing, laboratory R&D, and biotech production, filling small-volume vials demands extreme dosing accuracy, zero liquid wastage, and strict sterility compliance. The Harsiddh Small Vial Filling Machine is an advanced, ultra-compact monoblock solution engineered specifically to process miniature glass and plastic vials (ranging from 1 ml to 30 ml). Combining precise liquid dosing with immediate rubber stoppering on a unified, high-efficiency rotary indexing platform, this machine minimizes environmental exposure and eliminates contamination risks in cleanroom settings.

High-Performance Small Vial Packaging Engineering

When handling high-value formulations such as injectables, vaccines, ophthalmic drops, diagnostic reagents, or essential oils, standard large-footprint machinery can cause unnecessary hold-up volume and floor space inefficiency. The Harsiddh Small Vial Filling Machine solves this challenge by establishing a tightly controlled, highly efficient packaging sequence in a single monoblock unit.

By placing liquid filling nozzles in immediate proximity to the rubber stoppering head, the machine drastically shortens the critical window of time that an open vial is exposed to atmospheric conditions.

Step-by-Step Operational Workflow & Technical Anatomy

[ In-feed Tray / Rotary Dial ] → [ Precision Liquid Dosing ] → [ Automated Stopper Placement ] → [ Discharge Tray ]

1. In-Feed & Starwheel Indexing

Sterile small vials are loaded onto the stainless steel in-feed loading tray or directly onto the smooth rotary index wheel. The starwheel mechanism precisely captures each vial, guiding it through the operational stations with zero glass-to-glass friction or risk of tipping.

2. High-Precision Volumetric / Peristaltic Filling

Once indexed beneath the diving filling nozzles, the machine delivers exact liquid volumes. The diving nozzle system descends into the neck of the small vial and performs bottom-up filling to prevent air entrapment, splashing, or foaming.

• Peristaltic Pump Option: Ideal for biologicals and sterile liquids, allowing liquid to pass through disposable tubing with zero contact with mechanical pump parts.
• Volumetric Piston Pump Option: Engineered for high repeatability with viscous or non-viscous liquids.

3. Automatic Vibratory Rubber Stoppering

Rubber stoppers are sorted via an integrated overhead vibratory bowl feeder and delivered down a precision-machined chute. A synchronized pick-and-place or vacuum-assisted mechanism places the rubber stopper firmly into the vial neck immediately after liquid dispensing, instantly sealing the product.

4. Controlled Outfeed Collection

Fully filled and stoppered vials are gently ejected via the discharge starwheel onto an outfeed collection tray, ready for downstream aluminum capping or labeling.

Salient Features

• Zero-Dead-Leg Fluid Path: Fluid contact parts are engineered with sanitary tri-clamp fittings and mirror-polished SS 316L for effortless Cleaning-in-Place (CIP) and Sterilization-in-Place (SIP).
• Tool-Less Changeover: Rapid adjustments between different small vial heights and diameters (e.g., 2ml, 5ml, 10ml, 20ml) with minimal change parts.
• Sub-Surface Diving Nozzles: Drip-free diving nozzles eliminate splashing on the vial rim, ensuring optimal rubber stopper sealing.
• Variable Speed Drive (VFD): Stepless speed regulation allows seamless synchronization with production volume demands.
• Emergency Safety & Interlocks: Integrated front panel emergency stop button and acrylic safety shields ensure operator safety during continuous operation.

Technical Specifications

Feature / Parameter	Specification
Model	HS-SVFM (Small Vial Series)
Production Speed	20 to 60 Vials / Minute (Depending on fill volume & product viscosity)
Filling Range	1 ml to 30 ml (Customizable up to 50 ml)
Filling Accuracy	±0.5% to ±1%
Dosing Mechanism	Volumetric SS 316L Syringes or Peristaltic Pump System
Applicable Vials	Tubular / Molded Glass Vials & Plastic Vials
Stopper Type	Full Stoppering (Standard) or Partial Stoppering (Lyophilization)
Contact Parts Material	Stainless Steel 316L / Silicone Tubing
Non-Contact Parts	Stainless Steel 304
Control System	PLC Controlled with Color HMI Touchscreen
Power Supply	220V / 415V, 3-Phase, 50/60 Hz
Air Consumption	2 to 4 CFM @ 6 Bar Pressure
Compliance	cGMP, WHO, US-FDA Standards

Why Choose the Harsiddh Small Vial Filling Machine?

Investing in the Harsiddh Small Vial Filling Machine equips your facility with a robust, reliable, and compliant packaging solution built for rapid return on investment:

• Drastic Cleanroom Cost Savings: Its compact footprint reduces the space required under expensive Laminar Air Flow (LAF) hoods and HVAC systems.
• Minimal Product Loss: High-accuracy micro-dosing pumps minimize residual product volume, saving costly active pharmaceutical ingredients (APIs).
• High Versatility: Perfect for pilot plants, R&D labs, clinical trial batches, and medium-scale commercial production.
• Complete Validation Documentation: Provided with full DQ, IQ, OQ, and PQ validation support to assist you in meeting global regulatory compliance.

Frequently Asked Questions