ZONESUN ZS-FAL180V14 GMP Vial Filling Line for Injectable Drugs and Vaccines

ZONESUN ZS-FAL180V14 GMP Vial Filling Line for Injectable Drugs and Vaccines

Description 

The ZONESUN ZS-FAL180V14 is a GMP-oriented vial filling line for injectable products, vaccines, veterinary drugs, and other sterile liquids. It integrates water purification, mixing, feeding, filling, stopper insertion, capping, crimping, and labeling in one automated system. A Class 100 laminar flow hood reduces contamination risks, and food-grade SUS304 stainless steel contact parts ensure hygiene. Servo-controlled ceramic piston pumps deliver ±0.02 ml accuracy at 30 ml fill volume. With dual-head filling and speeds of 3,600–4,800 vials/hour, the line offers customizable filling ranges, tank capacities, and head configurations for diverse pharmaceutical needs.

Specifications

• Water Purification (ZS-WP500L) Capacity: 500 L/H Purified Water Conductivity: 1–10 μS/cm Power: 220V, 50Hz
• Jacketed Mixing Tank (ZS-VMB100RH) Capacity: 100 L (customizable) Material: SUS316L contact parts Mixing Speed: 0–62 RPM
• Vial Filling Crimping (ZS-AFC39F) Speed: 60–80 bottles/min Filling Heads: 2 Filling Range: 30 ml (customizable) Accuracy: ±3%
• Labeling (ZS-TB821) Speed: 40–120 bottles/min Labeling Accuracy: ±1.0 mm

Key Features

• Full Line Integration: Seamlessly combines water purification, mixing, feeding, liquid filling, stopper placement, capping, crimping, and labeling into a single continuous automated line.
• Class 100 Laminar Flow Protection: Features an integrated Class 100 laminar flow hood to maintain ultra-clean air conditions and prevent contamination during sterile filling.
• Ultra-Precise Ceramic Pump Dosing: Equipped with servo-controlled ceramic piston pumps delivering extreme accuracy of $\pm0.02\text{ ml}$ (at $30\text{ ml}$ volume).
• High-Speed Dual-Head Output: Dual-head filling architecture achieves impressive speeds of 3,600 to 4,800 vials per hour for high-capacity manufacturing.
• GMP-Compliant Hygienic Build: Constructed with food-grade SUS304 stainless steel liquid contact parts, meeting strict hygienic standards for medical products.
• Customizable Modular Setup: Offers tailor-made filling volume ranges, mixing tank capacities, and filling head counts to suit specific pharmaceutical workflows.

Benefits

• Turnkey Packaging Automation — Connects every stage from liquid preparation to final labeling, reducing manual handling and labor expenses.
• Uncompromised Sterile Hygiene — Laminar flow enclosure and sanitary ceramic components satisfy rigorous international pharma safety standards.
• Unrivaled Dosing Precision — High-grade ceramic pumps eliminate liquid dripping and guarantee ultra-consistent dosage per vial.
• High-Throughput Performance — Fast dual-lane processing delivers up to 4,800 vials/hour to easily fulfill large commercial production orders.
• Flexible & Scalable Design — Customizable modules allow seamless adaptation to diverse vial sizes, liquid viscosities, and operational requirements.

Applications

Perfect for pharmaceutical plants, biotechnology companies, and veterinary drug manufacturers packaging sterile liquid products into glass vials. Ideal for injectable solutions, vaccines, biological serums, antibiotic fluids, eye drops, and high-value veterinary medicines. Suitable for standard pharmaceutical glass vials requiring tight stoppering, crimp capping, and aseptic filling.

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 ZONESUN ZS-FAL180V14?

✅ Complete GMP Vial Filling Line — Integrated Sterile Production Solution: Combines water purification, mixing, liquid feeding, filling, stopper insertion, capping, crimping, and labeling into one automated system, providing a complete production solution for sterile injectable products and reducing manual transfer processes

✅ Class 100 Laminar Flow Hood — Enhanced Sterile Protection: Equipped with a Class 100 laminar airflow system to create a controlled clean environment, reducing contamination risks during vial filling and supporting strict pharmaceutical production requirements

✅ Servo-Controlled Ceramic Piston Pumps — ±0.02 ml High Filling Accuracy: Advanced servo-driven ceramic piston pumps provide precise and stable dosing performance with accuracy up to ±0.02 ml at 30 ml filling volume, minimizing product waste and ensuring consistent medication dosage

✅ Dual Filling Heads — High-Efficiency Vial Processing: Features two filling heads operating simultaneously to improve production efficiency, achieving speeds of 3,600–4,800 vials per hour while maintaining reliable filling consistency

✅ Automated Stoppering, Capping & Crimping — Complete Vial Sealing Process: Integrates stopper insertion, cap placement, and aluminum crimping into the automated line, ensuring secure vial closure and improving packaging efficiency for sterile products

✅ Food-Grade SUS304 Stainless Steel Contact Parts — Hygienic Construction: Product-contact components are made from food-grade SUS304 stainless steel, offering corrosion resistance, easy cleaning, and reliable hygiene performance for pharmaceutical manufacturing environments

✅ Customizable Filling Configurations — Flexible Production Adaptation: Supports customized filling ranges, tank capacities, and filling head configurations, allowing manufacturers to adapt the system for different vial sizes, liquid volumes, and production requirements

✅ Integrated Labeling System — Complete Finished Vial Packaging: Includes automatic vial labeling capability to improve production efficiency, product identification, and traceability throughout the pharmaceutical packaging process

Ideal Applications

Pharmaceutical Injectable Products: Ideal for filling and packaging injectable medicines, sterile solutions, and pharmaceutical liquids requiring high filling accuracy, contamination control, and GMP-oriented production standards

Vaccines & Biological Products: Suitable for vaccine filling applications and other sensitive biological liquids requiring a controlled clean environment and precise sterile handling processes

Veterinary Pharmaceuticals: Designed for veterinary drug production, including injectable veterinary medicines requiring reliable dosing accuracy and automated vial packaging

Medical & Healthcare Manufacturing: Applicable for sterile liquid products, diagnostic solutions, and healthcare-related formulations requiring consistent filling, sealing, and labeling performance

Sterile Liquid Production Facilities: Provides a complete automated vial processing solution for pharmaceutical factories seeking improved efficiency, reduced manual operation, and stable large-scale production capability