Working of Vial Filling Machine

A vial filling machine, also called a vial filler machine, is an electromechanical equipment that is specifically designed to fill products in vials.

Vial filler is a common packaging equipment in most pharmaceutical and drug industries.

How Vial Filler Machine Works

Empty and Filled Vials
Empty and Filled Vials

The vial filler machines package liquid or powder in very distinct steps. These stages may vary depending on the machine’s design and configurations.

Let’s look at some critical steps:

Step 1: Preparation

Vials Filling Line
Vials Filling Line

This is the first step during vial filling. In this process, the vial filling machine is cleaned and sanitized.

Secondly, the machine is set up according to the specification of the product you intend to fill. Remember, you can fill powder or liquid in vials.

Thirdly, ensure there is enough supply of vials caps, and other components.

Step 2: Vial Loading

Place the empty vials onto the conveyor or the loading system of the machine. You can do this manually or use an automatic loading system.

To avoid jams and collisions, ensure there is space between the vials. In addition, the vials are placed in a specific direction to ensure proper filling.

Vials in Loading Chamber
Vials in Loading Chamber

Step 3: Product Feeding

The products are filled depending on the nature of the material.

Step 4: Filling

In this stage, the vials move through the filling station, and the product is dispensed on each vial.

For accuracy, the filling process is controlled by volume and weight. The filling station also contains multiple heads or nozzles that enable faster vial filling without any waste.

There are different types of filing during this stage including;

  • Liquid filling: For liquids, the machine uses different types of methods such as gravity fillings, and piston fillings among others.
  • Powder filling: For powder, the machine uses different types of methods such as vacuum fillings, and auger fillings among others,

Step 5: Leveling/Compacting

In this step, the leveling or compacting helps to ensure uniform filling and helps to remove air bubbles.

Step 6: Capping

Once it is filled with the specific product (powder or liquid)the vials move to the capping station.

In this process, the caps are then placed on the vials and sealed securely.

The sealing process involves different stages like placing a rubber stopper on the vial for liquid products or attaching a cap for powder products.

Step 7: Inspection

Inspection involves several processes like;

  • Checking proper fill levels
  • Confirming the overall quality
  • Cap replacements.

This stage helps to identify and reject vials with any defects.

Step 8: Labeling and Coding

In this stage labelling and coding are done are applied to the vials.

Step 9. Packaging

After the products have been labeled and coded, they are then packed into the final packaging. You can package the vials in boxes.

Step 10. Quality Control

Quality control measures are implemented to ensure the products adhere to or meet the required standards and specifications.


Vial filling machines consist of multiple filling stages as mentioned above. This helps to complete the process while increasing productivity.

Vial filling is one of the most popular product packaging solutions we offer at LOM. For any custom packaging solutions, contact us now.

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