Vial filling machines for Annex 1-compliant pharma production

A vial filling machine is a pharmaceutical system that doses liquid drug products into vials and closes them under aseptic conditions. It is a key component for the safe, precise and efficient processing of liquid medicines such as biologics, vaccines and other high-value products.

Bausch+Ströbel vial filling machines cover requirements from small clinical batches to commercial production. They are designed for pharmaceutical companies, biotech manufacturers and CDMOs that need flexibility and process reliability.

An aseptic vial filling machine fills and closes vials while maintaining stable, aseptic process conditions. At Bausch+Ströbel, pre-sterilised packaging materials enter the class A area via no-touch transfer (NTT), so additional disinfection or bio-decontamination is not required.

The product is then dosed using a rotary piston pump, a peristaltic pump or time-pressure dosing, and the vials are closed. Options such as vacuum-assisted filling and closing or adjustable gas flushing support optimum results. Automatic in-process control checks the dosing quantity during filling and closing.

Ready-to-use (RTU) vials are delivered pre-sterilised. They offer maximum sterile safety and short set-up times, because they go directly into the aseptic process without time-consuming preparation steps.

Bulk vials offer an economic advantage for large quantities and commercial production. With our flexible production platforms, you can process vials in both nest and bulk on one platform, which gives you room to adapt to different products and batch sizes.

Our vial filling machines cover a wide performance range, from small clinical batches to commercial production with an output of up to 30,000 vials per hour.

The modular machine concepts and scalable performance ranges let the solution grow with your requirements, from development to fully automated large-scale production. The achievable output depends on the machine configuration, the vial format and the product.

Our vial filling machines are ideal for complex liquid products such as biologics, vaccines and high-value medicines, where gentle handling and loss-free processing are essential.

Different dosing technologies allow accurate filling of both water-like and highly viscous products, so the system can be matched to the characteristics of your formulation.

For every product, a suitable dosing system is available: rotary piston pump, peristaltic pump or time-pressure dosing. Vacuum-assisted filling, vacuum-assisted closing and adjustable gas flushing can be added for optimum filling results.

The fully automatic statistical in-process control (IPC) checks the dosing quantity during the filling and closing process. If under- or overdosing occurs, the dosing quantity is readjusted automatically. To further reduce product loss, take a look at our AdvancedFill solution.

Our no-touch transfer (NTT) enables the GMP-compliant introduction of pre-sterilised packaging materials in double bags into the class A area. The process is fully compliant with EU GMP Annex 1 and is based on the principles of quality risk management in accordance with ICH Q9.

Together with aseptic machine design and integrated process control, this helps you combine regulatory safety with economic efficiency. For the complete route from process to patient, discover our Integrated Solutions.