High-Precision, Compact Two-Head Liquid Filling & Rubber Stoppering Machine for Pharmaceutical, Biotech, and Injectable Lines
The Harsiddh Two Head Liquid Vial Filling Stoppering Machine is an advanced, high-precision monoblock liquid packaging solution designed specifically for pharmaceutical cleanrooms, biotech facilities, and injectable manufacturing lines. Combining dual-head volumetric liquid filling with automated rubber stoppering on a synchronized rotary starwheel platform, this machine delivers consistent dosing accuracy, reliable sealing, and high operational efficiency while maintaining a minimal cleanroom footprint.
High-Performance Packaging Engineering for Sterile Liquids
In sterile pharmaceutical manufacturing, minimizing contamination risks and maximizing filling accuracy are critical parameters. The Two Head Liquid Vial Filling Stoppering Machine addresses these challenges by merging two essential operations—liquid dispensing and rubber stoppering—into a single compact monoblock frame.
By placing the dual-head liquid filling station in direct proximity to the rubber stoppering indexing wheel, the machine eliminates transit delays between filling and sealing. This drastically reduces the open time of sterile vials and lowers cleanroom airflow turbulence.
Operational Workflow & System Architecture
[ In-feed Turntable / Tray ] → [ 2-Head Precision Filling ] → [ Automatic Stopper Placement ] → [ Discharge Tray ]1. In-Feed & Vial Indexing
Sterile vials are automatically fed from an in-feed turn table or loading tray onto a precision-machined rotary starwheel. The starwheel smoothly indexes two vials simultaneously into the filling zone without glass-to-glass damage or tipping.
2. Dual-Head Diving Filling Sequence
Two volumetric piston pumps (or peristaltic pumps) descend into the vial necks using sub-surface diving nozzles. Bottom-up filling prevents splashing, foaming, or liquid droplets on the vial rim, ensuring a tight seal during stoppering.
3. Automatic Vibratory Rubber Stoppering
Rubber stoppers are sorted in an overhead vibratory bowl and delivered down a precision chute. Synchronized pick-and-place rubber stoppering heads firmly press stoppers into the vial necks as soon as liquid filling completes.
4. Smooth Discharge
Fully filled and stoppered vials are indexed out of the starwheel onto an outfeed tray or directly onto an interconnected aluminum cap sealing conveyor.
Salient Features
- Zero-Drip Diving Nozzles: Positively driven diving nozzles ensure clean cutoff with zero dripping, maintaining hygienic bottle shoulders.
- Sanitary Tri-Clamp Fittings: All fluid pathways utilize sanitary tri-clamp connections for fast disassembly, CIP (Clean-in-Place), and SIP (Sterilization-in-Place).
- Tool-Less Changeover Parts: Fast starwheel and guide rail adjustments for processing various vial sizes (e.g., 2 ml, 5 ml, 10 ml, 20 ml, 30 ml, 50 ml, and 100 ml).
- Variable Speed Control: AC variable frequency drive allows smooth speed adjustments up to 50–60 vials per minute depending on fill volume and viscosity.
- Safety Enclosure: Acrylic or glass safety doors with safety interlocks protect operators and preserve internal airflow stability during production.
Technical Specifications
| Feature / Parameter | Specification |
|---|---|
| Model | HS-LVFS-2H (Two Head Series) |
| Production Capacity | 30 to 60 Vials / Minute (Varies by fill size and liquid viscosity) |
| Number of Heads | 2 Liquid Filling Nozzles + 1 Stoppering Unit |
| Filling Range | 2 ml to 100 ml (With suitable piston pump change parts) |
| Filling Accuracy | ±0.5% to ±1% |
| Applicable Containers | Molded & Tubular Glass Vials / Plastic Vials |
| Stopper Types | Rubber Stoppers (Full Stoppering or Partial Lyophilization Stoppering) |
| Contact Parts Material | Stainless Steel 316L / Silicone Tubing |
| Non-Contact Frame | Stainless Steel 304 |
| Control System | Siemens / Allen-Bradley PLC with Touchscreen HMI |
| Power Supply | 415V / 220V, 3-Phase, 50/60 Hz |
| Air Supply | 4 to 6 Bar Compressed Air |
| Compliance | cGMP, WHO, US-FDA Standards |
Benefits of the Two Head Monoblock Solution
- Space-Saving Design: Combines two processing steps into one frame, freeing up valuable floor space in Class 100 / Grade A cleanrooms.
- Reduced Labor & Contamination: Automated feeding, filling, and stoppering reduce manual handling and human contamination risks.
- High ROI for Mid-Scale Production: Ideal for clinical batches, pilot plants, biological injectables, ophthalmic solutions, and medium-scale commercial manufacturing.
- Complete Regulatory Support: Supplied with complete DQ, IQ, OQ, and PQ documentation sets for seamless regulatory approval.
Frequently Asked Questions
Can this machine perform both full stoppering and half (partial) stoppering?
Yes. The stoppering height and pressure can be adjusted to perform full stoppering for standard liquid injectables or partial stoppering for freeze-dried (Lyophilization) products.
Can this machine handle both volumetric piston pumps and peristaltic pumps?
Yes. Depending on your product characteristics, we can equip the unit with SS 316L volumetric syringes for precise volumetric dosing or peristaltic pumps for sensitive biological products that require disposable fluid pathways.
What happens if a vial is missing at the filling station?
The machine features integrated optical sensors for "No Vial – No Fill" and "No Vial – No Stopper". If a vial position is missing on the rotary wheel, the corresponding filling nozzle and stopper head will pause for that cycle to prevent product waste and machine contamination.
How long does it take to perform a changeover for different vial sizes?
With tool-less change parts, changing over between different vial sizes (e.g., from 5 ml to 20 ml) takes approximately 15 to 25 minutes.