Built with a GMP-compliant structure, ZONESUN provides vial filling machines and related packaging system supporting automatic vial fiilling, half stoppering (suitable for process that require preparation before freeze drying) or full stoppering, flip-off caps crimping. With flexiblle configurations, ZONESUN vial filling machine can work operate as standalone unit or be intergrated into a complete vial packaging line, including downstream labeling and cartoning systems. ZONESUN vial filling machine is designed for precise liquid or powder dosing while minimizing contamination risk across laboratory, biotech, and pharmaceutical environments.
Applications of Vial Filling Machine
ZONESUN vial filling machine is widely used for:
- Vaccines
- Antibacterial Solution
- Injectable liquids
- Biotech and biological solutions
- Freeze-dried (lyophilized) products
- Laboratory and pilot-scale production
- High-value cosmetic and skincare serums packaged in vials
The system is also suitable for cosmetic liquids that require precise dosing and contamination control.
Case Study of Vial Filling Machine
A U.S. nutritional supplement manufacturer needed a high-speed vial filling solution for liquid muscle-strengthening supplements intended for freeze-drying (lyophilization).
The customer was using compact 2 mL glass vials, size is Ø16 mm × H34.7 mm, with Ø12 mm rubber stoppers and Ø14.7 mm aluminum flip-off caps. The existing line of this US manufacturer ran at about 35–40 vials per minute (VPM), but they planned to boost output to 45–60 VPM while maintaining stable filling accuracy within ±1%.
Since the product required lyophilization, the system also had to support half-stoppering before freeze-drying and final crimp sealing afterward. On top of that, the customer wanted optional HEPA laminar flow protection, and less need for operator adjustments during continuous high-speed production.
Key Features of Vial Filling Machine
Designed for Lyophilization Workflow
- Supports filling and half stoppering before freeze drying
- Maintains vial stability during transfer
- Compatible with standard lyophilization processes
High-Speed Automatic Production
- Stable output: 1000 – 3600 vials/hour
- Maximum capacity: up to 12000 vials/hour
- Multi-head filling configuration available
Sterile-Oriented Filling Design
- Peristaltic pump with disposable tubing
- Optional laminar flow hood
- Reduced contamination risk during filling
Advanced Servo-Controlled Filling
- Servo-driven peristaltic pump system
- Digital parameter control via HMI
- Improved stability and repeatability
Compared with conventional time-based filling, servo control provides more consistent performance and easier calibration.
Flexible System Integration
- Can operate as:
- Standalone filling unit
- Filling and stoppering system
- Integrated part of a filling and crimping line
- Compatible with labeling machine and downstream equipment
How the ZONESUN Vial Packaging System Works
The ZONESUN vial packaging system is designed to support the complete vial processing workflow before and after lyophilization.
1. Vial Feeding
Automatic vial feeding system ensures continuous and stable bottle input.
2. Liquid or Powder Filling
- Peristaltic pump dosing (liquid)
- Sscrew auger filling (powder)
- Servo-controlled filling process
- Suitable for small to medium volume applications
3.Half Stoppering & Full Stoppering
The ZONESUN vial filling machine supports both half-stoppering and full-stoppering modes, depending on production requirements.
For lyophilization applications, vials are typically processed with half stoppering to allow moisture removal during freeze drying.
For other production processes, the system can operate in full stoppering mode, enabling a continuous workflow with direct integration to the capping and crimping unit for complete sealing in one line.
4. Transfer to Lyophilization (If Required)
Vials are transferred to the freeze dryer while maintaining stopper position.
5. Post-Lyophilization Sealing
After drying:
- Final stoppering is completed
Aluminum caps are applied and crimped (via separate equipment)
ZONESUN Vial Filling System
- Peristaltic pump driven by servo motor
- Interchangable screw auger
- Stable and repeatable dosing performance
- Suitable for aqueous and sensitive liquids or powdered products
Filling Accuracy:
Up to ±1% (depending on product, tubing, and calibration)
For very small volumes, actual results may vary slightly due to tubing elasticity, filling material characteristics, and operating conditions.
Stoppering & Sealing System
- Automatic rubber stopper placement (half stoppering or full stoppering)
- Vibratory feeder with adjustable settings
- Servo-assisted pick-and-place mechanism
- Compatible with aluminum caps for post-process sealing
Machine Construction
- Product contact parts: SUS316 stainless steel
- Frame and structure: SUS304 stainless steel
- Hygienic design for easy cleaning
- Built according to GMP-oriented design principles
Container Compatibility
- Supports multiple vial sizes
- Typical formats: 2ml vial / 5ml vial / 10ml vial / 20 ml vial / 50 ml vial
- Standard neck size: 20 mm (other sizes are customizable)
- Change parts available for different containers
Optional Features
- Laminar flow hood
- Enclosed filling area
- Automatic reject system
- Multi-head filling system
- Integration with capping , labeling and cartoning machines
- Mobile structure with caster wheels
Peristaltic Pump Advantage
- No direct contact between pump and liquid
- Easy tubing replacement (single-use possible)
- Reduced cleaning requirements
- Suitable for sterile or sensitive applications
FAQ of Vial Filling Machine
1. Can this vial filling machine be used for lyophilized products?
Yes. The system supports filling and half stoppering before freeze drying and can be integrated with freeze dryers.
2. How is the filling volume controlled?
Automatic models use servo-controlled peristaltic pumps for stable and repeatable dosing.
Semi-automatic models typically rely on time-based adjustment of filling duration and pump speed.
3. What is the filling accuracy?
Typically up to ±1%, depending on product properties, tubing, and calibration.
4. Is ZONESUN vial filling machine suitable for sterile applications?
Product-contact parts of the ZONESUN vial filling machine are made of SUS304 and SUS316 stainless steel. Laminar flow protection and disposable tubing help minimize the risk of contamination.
5. Can it be integrated into a production line?
Yes. It can work with upstream and downstream equipment, including vial labeling machine, and cartoning systems.
ZONESUN vial filling machine is designed to support precise and flexiblevial processing and packaging solution across a wide range of applications, from laboratory use to automated production environments. Its modular design allows seamless integration with upstream and downstream equipment, helping manufacturers build efficient and scalable production lines .
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