Common faults and solutions for vial filling and capping machines

In the pharmaceutical industry, precise and efficient packaging is crucial. The vial filling and capping machine is such an automated equipment that can meet these needs. Its main operating components work together to ensure the efficiency and accuracy of the automatic filling, stoppering and capping processes of vials.

Its main operating components include peristaltic pumps, aliquot plates, filling heads, plug pressing devices, capping devices, conveying devices and control systems. Among them, the peristaltic pump is responsible for accurately controlling the filling volume of the liquid, while the aliquot plate is used to position and distribute the vials to each filling position. The filling head accurately fills the liquid into the vial, the stopper is used to press the stopper into the bottle mouth, and the capping device is responsible for tightening the bottle cap. The conveying device continuously moves the vials during the entire process to ensure that they pass through each link smoothly. The control system, usually including PLC and touch screen, is responsible for the control of the overall operation. In addition, sensors also play a key role in detecting the location, quantity and other information of vials to ensure the normal operation of the machine. The close cooperation of these components enables the automatic filling, stoppering and capping processes of vials to be completed efficiently and accurately.

The efficient operation of vial filling, corking and capping machines is of great significance to ensuring the quality and efficiency of pharmaceutical production. However, during use, it is inevitable to encounter some common faults. Below, we will discuss these faults and their corresponding solutions in detail.

1. Inaccurate filling is a common problem. This is usually due to erratic flow from a peristaltic pump or a problem with the filling valve's valving. In order to solve this problem, we need to carefully check the working status of the peristaltic pump to ensure that its flow rate is stable and meets the set requirements. At the same time, also check whether the filling valve is tightly closed and whether there is any leakage. If problems are found, repairs or parts should be replaced in time.

2. Unstable press-in of the plug is also a headache. This may be due to insufficient strength of the plug pressing device or quality problems with the plug itself. To solve this problem, we can first adjust the strength of the cork pressing device to ensure that it can provide sufficient pressure to press the cork into the bottle. If adjusting the force still does not solve the problem, then you need to consider replacing the plug with a high-quality one.

3. The lid is not tightly tightened and is also a problem that cannot be ignored. This may be caused by insufficient strength of the screw capping mechanism or the size of the cap itself. In this case, we need to first check the force setting of the capping device to ensure that it can provide sufficient rotational force to tighten the cap. If enough force doesn't resolve the problem, it may be time to replace the cap with one that meets the size requirements.

4. Conveying device failure is also one of the common problems of vial filling, corking and capping machines. This may be caused by a broken conveyor chain or a faulty motor. In this case, we need to replace the broken conveyor chain in time and check the working status of the motor to ensure its normal operation. If the motor fails, it also needs to be repaired or replaced in time.

5. Control system failures are also issues that require attention. This could be due to a faulty sensor or a problem with the controller itself. To solve this problem, we need to check all components of the control system, including sensors and controllers, to make sure they are working properly. If any faulty or damaged parts are found, they need to be repaired or replaced promptly.

In short

Common faults of vial filling and capping machines and their solutions are knowledge that we must master. Only through regular maintenance and timely handling of faults can the normal operation of the equipment and the smooth progress of pharmaceutical production be ensured.