Description
The ZONESUN ZS-FAL180V14 Automatic Vial Filling Production Line is designed for integrated filling and packaging of compatible liquid products in vials. The line combines water preparation, product mixing, vial feeding, liquid filling, stopper insertion, aluminum-cap handling, crimping and downstream labeling in one connected production system.
The core filling section uses dual ceramic plunger pumps with servo control, while the vial handling section coordinates filling, stoppering and cap crimping in a continuous workflow. The system can be configured around different vial sizes, filling volumes, tank capacities, closure formats and production requirements.
Technical Overview
| Line Model | ZS-FAL180V14 |
|---|---|
| Main Line Sections | Water purification / mixing / vial filling / stopper insertion / cap feeding / crimping / labeling |
| Main Filling Machine | ZS-AFC39F |
| Filling Pump | Ceramic plunger pump |
| Filling Nozzles | 2 |
| Reference Filling Volume | 30 ml, customizable |
| Working Speed | Approx. 60–80 vials/min |
| Water Purification Capacity | 500 L/h |
| Labeling Speed | Approx. 40–120 bottles/min |
| Power Options | 110V / 220V for individual machines; line configuration customizable |
Detailed Machine Specifications
Water Purification System — ZS-WP500L
- Power Supply: 220V, 50Hz (customizable)
- Purified Water Conductivity: 1–10 μS/cm (25°C)
- Production Capacity: 500 L/h
- Desalination Rate: 95%
- Recovery Rate: 50–60%
- Machine Dimensions: Approx. 1900 × 650 × 1650 mm
- Weight: Approx. 488 kg
Vial Filling & Crimping Machine — ZS-AFC39F
- Voltage: 110V / 220V, 50–60Hz
- Power: <3000 W/h
- Working Speed: Approx. 60–80 bottles/min
- Filling Pump: Ceramic Plunger Pump
- Filling Nozzles: 2
- Filling Range: 30 ml (customizable)
- Filling Accuracy: ±3%
- Machine Dimensions: Approx. 2660 × 1700 × 2150 mm
Labeling Machine — ZS-TB821
- Voltage: 110V / 220V, 50–60Hz
- Power: 570 W
- Labeling Accuracy: ±1.0 mm
- Labeling Speed: Approx. 40–120 bottles/min
- Applicable Bottle Diameter: φ25–φ120 mm
- Label Size: W 20–300 mm × H 20–95 mm
- Machine Dimensions: Approx. 2040 × 1180 × 1370 mm
- Weight: Approx. 330 kg
Water Purification System
Removing impurities and dissolved minerals from source water before production, providing purified process water and reduce contamination risks.
Mixing System
Custom-designed mixing tanks ensure ingredients remain uniformly blended throughout production, customizable working capacity.
Servo Ceramic Plunger Pump
Powered by servo-controlled ceramic plunger pumps, the system delivers precise and repeatable dosing with filling accuracy up to ±0.02 ml (at 30 ml filling volume).
Vibratory Feeding System
Automatically orients and supplies rubber stoppers and aluminum caps to ensure uninterrupted high-speed production.
Cam Driven System
Cam mechanism coordinates all working stations (stopper insertion, stopper pressing and caps crimping) simultaneously, ensuring 60-80 BPM high working capacity.
Side Belt Labeling Structure
Designed for self-adhesive sticker, it is suitable for side labeling of vials, reach high labeling accuracy and speed.
Laminar Flow Hood
Provides localized ISO Class 5 (Class 100) clean airflow above the filling area, effectively reducing airborne particle contamination and helping maintain aseptic filling conditions.
Why Choose the ZS-FAL180V14?
✅ Complete End-to-End Vial Packaging Line — 8 Processes in 1: Water purification → mixing → vial feeding → dual-head filling → stopper insertion → capping → crimping → labeling all integrated in one automated production line — eliminating inter-process manual handling and ensuring sterile product integrity throughout
✅ Class 100 Laminar Flow Hood — Sterile Filling Environment: Integrated Class 100 (ISO 5) laminar flow protection over the filling zone minimizes airborne contamination risk during vial filling and stopper insertion, meeting GMP sterile manufacturing environment requirements for injectable and vaccine products
✅ Ceramic Piston Pump — ±0.02 ml Filling Accuracy: Servo-controlled ceramic plunger pump delivers ±0.02 ml filling accuracy at 30 ml fill volume — meeting the stringent dosing precision requirements of pharmaceutical injectable products, vaccines, and sterile liquid formulations
✅ 3,600–4,800 Vials/Hour Dual-Head Output: Dual filling head configuration achieves 60–80 bottles/min (3,600–4,800 vials/hour), providing high-volume pharmaceutical production throughput for commercial injectable and vaccine manufacturing operations
✅ SUS304 Food-Grade Stainless Steel — GMP Compliant: All product-contact surfaces are SUS304 stainless steel, meeting pharmaceutical GMP hygiene standards for sterile liquid filling, stopper insertion, and capping in regulated pharmaceutical manufacturing environments
✅ Integrated Water Purification (500 L/h, 95% Desalination): Built-in ZS-WP500L water purification system produces 500 L/h of purified water with 1–10 μS/cm conductivity and 95% desalination rate — providing on-site pharmaceutical-grade water for product mixing and equipment rinsing
✅ Customizable Filling Range, Tank Capacity & Head Configuration: Filling range, hopper tank capacity, number of filling heads, and line configuration are all customizable to match specific pharmaceutical product requirements, vial sizes, and production volume targets
Ideal Applications
Injectable Pharmaceutical Products: GMP-compliant vial filling, stoppering, capping, crimping, and labeling of injectable drugs, biologics, and sterile pharmaceutical liquids requiring Class 100 laminar flow protection and ceramic piston pump precision
Vaccine Manufacturing: Sterile vial filling and sealing for human and veterinary vaccines requiring aseptic filling conditions, precise dose accuracy, and complete end-to-end automated vial packaging from water purification to labeled finished product
Veterinary Drug Packaging: Automated vial filling and packaging of veterinary injectable drugs, animal vaccines, and veterinary sterile liquid products requiring GMP-compliant filling accuracy and hygienic stainless steel contact surfaces
Ophthalmic & Biological Products: Sterile vial filling for ophthalmic solutions, biological products, protein formulations, and other sensitive sterile liquids requiring Class 100 laminar flow protection and ±0.02 ml dosing accuracy
Contract Pharmaceutical Manufacturing: Complete vial packaging line for pharmaceutical contract manufacturers (CMOs), generic drug producers, and specialty pharmaceutical companies requiring flexible, customizable GMP vial filling and packaging capacity
How the Vial Filling Line Works
Prepared liquid is supplied to the filling section, where vials are indexed through filling, stopper insertion and cap crimping. Finished vials are then transferred to downstream labeling. Water preparation and mixing equipment can be included upstream according to the process requirements.
Best-Suited Applications
The ZS-FAL180V14 is intended for compatible liquid products packed in vials where automatic filling, stoppering, crimping and labeling are required as one connected line. The exact configuration should be selected according to the vial, closure system, product properties and production requirements.
Why Use Ceramic Plunger Pumps?
Ceramic plunger pumps are commonly selected for precise small-volume liquid dosing because they provide controlled displacement and good chemical resistance. The suitable pump size and filling range should be matched to the product and target volume.
Inline Filling and Crimping vs Separate Machines
An integrated vial filling and crimping machine coordinates multiple packaging steps within one platform, reducing transfer points between filling, stopper insertion and cap crimping. Separate machines may provide more flexibility for highly varied processes but require additional conveying and synchronization.
Before Ordering, Please Confirm
- Vial sample and dimensions
- Target filling volume
- Product viscosity and formulation
- Rubber stopper sample and dimensions
- Aluminum cap sample and dimensions
- Required production speed
- Required filling accuracy
- Required upstream water-preparation or mixing equipment
- Required downstream labeling or inspection equipment
- Clean-area and airflow requirements
- Factory voltage and production-line layout
Frequently Asked Questions
What processes are included in the ZS-FAL180V14 line?
The listed configuration includes water preparation, mixing, vial filling, stopper handling, cap crimping and labeling.
What filling pump is used?
The main filling machine uses ceramic plunger pumps.
What is the listed filling speed?
The core filling and crimping machine is listed at approximately 60–80 vials/min.
Can the filling range be customized?
Yes. The current 30 ml reference filling range can be adjusted through a customized pump and machine configuration.
Can the line include localized clean-air protection?
Yes. A laminar-flow hood option is listed for the filling area. The required clean-area classification and site conditions should be confirmed for the project.
Can the line be configured for different vial sizes?
Yes. Vial handling, stopper feeding, cap feeding and labeling components can be evaluated according to the actual vial and closure samples.
Need Help Confirming the Vial Filling Line?
Send us your vial, stopper and cap samples, product information, target filling volume, required speed and factory layout. We can help confirm the appropriate ZS-FAL180V14 line configuration.
