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    ALF 5000 V _11_V2

    Vial filling machines for Annex 1 compliant line solutions

    One line, any vial, with maximum flexibility for Annex 1 compliant aseptic production.

    Connect with vial filling experts Vial filling downloads

    Keep vial filling lines flexible across batches and formats

    Syntegon vial filling machines are part of end-to-end, seamlessly integrated lines that adapt to changing vial formats, batch sizes, and containment concepts.

    Our equipment enables rapid format changes, multiproduct processing, and simpler (re-)validation through integrated isolator, freeze-drying, and inspection solutions. With more than 1,500 installations worldwide, we help you boost capacity while staying flexible, efficient, and fully regulatory ready.

    Vial filling machines: flexibility, compliance and dosage range

    How to combine vial line flexibility and speed?

    Flexible vial filling lines stay fast from small to large batches.

    How to design vial filling lines for Annex 1 compliant operations?

    Aseptic vial filling lines with barriers and inspection support Annex 1 needs.

    How to handle different dosage forms on one vial line?

    One vial filling line handles liquid, lyophilized, oily and viscous products.

    End-to-end vial filling lines for flexible Annex 1 compliant production

    ALF_with_Telstar_FD_2

    Formulation and pure media for product safety

    Prepare liquid formulations and WFI to protect product quality and feed your vial filling line reliably.
    Formulation solutions

    Vial pretreatment

    Clean, sterilize and depyrogenate vials so they enter the filling machine particle-free and ready for high-speed processing.
    Cleaning solutions

    Filling and closing for flexible vial batches

    Fill and close vials in an Annex 1 compliant filling machine with changeovers that support many formats while limiting interventions.
    Compare solutions

    Freeze drying integrated into your vial line

    Transfer filled vials to freeze-dryers with automated loading to cut handling risk and support stable lyophilization.
    Freeze drying solutions

    Isolator technology that limits interventions

    Separate operators from the aseptic area with isolators or RABS designed to help you meet applicable regulations.
    Isolator solutions

    Inspection that secures batch release

    Use inline and end-of-line inspection to detect particles, cosmetic defects and leaks early so you protect every batch.
    Inspection solutions

    Sterilization that supports aseptic safety

    Apply dry heat sterilization for components so your aseptic area receives sterilized equipment.
    Sterilization solutions
    ALF_with_Telstar_FD_2

    Formulation and pure media for product safety

    Prepare liquid formulations and WFI to protect product quality and feed your vial filling line reliably.
    Formulation solutions
    ALF_with_Telstar_FD_2

    Vial pretreatment

    Clean, sterilize and depyrogenate vials so they enter the filling machine particle-free and ready for high-speed processing.
    Cleaning solutions
    ALF_with_Telstar_FD_2

    Filling and closing for flexible vial batches

    Fill and close vials in an Annex 1 compliant filling machine with changeovers that support many formats while limiting interventions.
    Compare solutions
    ALF_with_Telstar_FD_2

    Freeze drying integrated into your vial line

    Transfer filled vials to freeze-dryers with automated loading to cut handling risk and support stable lyophilization.
    Freeze drying solutions
    ALF_with_Telstar_FD_2

    Isolator technology that limits interventions

    Separate operators from the aseptic area with isolators or RABS designed to help you meet applicable regulations.
    Isolator solutions
    ALF_with_Telstar_FD_2

    Inspection that secures batch release

    Use inline and end-of-line inspection to detect particles, cosmetic defects and leaks early so you protect every batch.
    Inspection solutions
    ALF_with_Telstar_FD_2

    Sterilization that supports aseptic safety

    Apply dry heat sterilization for components so your aseptic area receives sterilized equipment.
    Sterilization solutions

    Explore the complete line

    Formulation & pure media
    Vial pretreatment
    Filling & closing
    Freeze drying
    Isolator
    Inspection
    Sterilization

    Compare our vial filling machines

    Overall 2 Solutions
    Output performance
    Format range
    Special features
    Changeover
    Filling systems
    Container types
    Barrier technologies and line integration
    Benefits
    ALF 5000 Vial Filling Machine
    ALF 5000
    Output performance
    600 c/min, 100 % IPC vials
    Format range
    Vials 0.2 to 100 milliliters, ampoules 1 to 30 milliliters
    Special features
    High-speed combi, gentle carry
    Changeover
    Fast tool-free changeover
    Filling systems
    Up to 12 heads, supports all filling systems
    Container types
    Vials, molded glass, ampoules
    Barrier technologies and line integration
    RABS or isolator, lyo option
    Benefits

    Best if you want:

    • Safe flexible high-speed combi line for ampoules and vials
    • 100 % IPC and modular platform for high-potent or complex aseptic products
    Specsheet
    FLC3000 Vial Filling Machine
    FLC 3000
    Output performance
    600 c/min, statistical IPC
    Format range
    Vials 0.2 to 500 milliliters
    Special features
    Compact, gentle vial transport
    Changeover
    Few parts, modular layout
    Filling systems
    Up to 12 heads, supports all filling systems
    Container types
    Vials, molded glass
    Barrier technologies and line integration
    RABS or isolator integration
    Benefits

    Best if you want:

    • Wide range, compact vial line for up to 500 milliliters
    • Compact medium to high output line for flexible layouts
    Specsheet
    Featured_Download_Teaser_Vials

    Master vial line flexibility and cut downtime

    Find out how to achieve flexibility in your vial line, from filling to freeze-drying.

    • Identify 5 key flexibility levers
    • Reduce changeover time
    • Plan modular, future-ready vial lines
    Download

    Vial filling machines that combine speed, flexibility and Annex 1 compliance

    _1220751 _1_ _1_

    Up to 600 vials/min without losing flexibility

    One flexible platform for 2–500 ml vials, from early clinical batches to high output commercial.
    Freeze-dryer

    One vial line from isolator to freeze dryer

    Cut interfaces and manual transfers with one integrated line from vial filling to inspection.
    R6_09669

    100 % inspection concepts integrated in your vial line

    Detect particles and leaks earlier with inline inspection, CCIT and empty-vial checks.
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    Case Study

    IDT Biologika boosts high speed vial capacity with Syntegon

    IDT Biologika needed a fast, flexible vial line. Syntegon enables the production of 80-100 million 2R vials per year with 100 % IPC.

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    Case Study

    Alcami doubles small batch vial capacity with turnkey line

    Alcami required a flexible Annex 1 compliant line for 2-50 ml vials. Syntegon's ARF isolator line more than doubled daily output at the Charleston site.

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    Case Study

    AJ Vaccines upgrades vial line for Annex 1 readiness

    AJ Vaccines modernized an existing vial line with Syntegon RABS and barrier upgrades designed to help meet Annex 1 expectations while keeping capacity available.

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    Case Study

    Aspen Pharmacare secures vaccine vial flexibility and scale

    Aspen Pharmacare partnered with Syntegon on a flexible vial filling line that increases sterile vaccine capacity and supports multiple vial formats for future launches.

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    Your strategic lifecycle partner for vial filling

    service-life-cycle
    Ready for everything from start to routine

    From installation to optimization, Syntegon supports you with structured service packages, training, and specialists – for safe, stable, and resilient production across the lifecycle.

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    service-life-uptime
    Secure availability every day

    Fast spare parts, qualified support, and preventive maintenance help you avoid unplanned downtime, protect performance, and keep daily operations reliable.

    Contact
    service-future-ready
    Make your line fit for tomorrow

    Scalable retrofits and data solutions help you adapt to new demands, improve OEE, and keep your lines future-proof across changing requirements.

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    Vial filling knowledge hub

    Vial filling portfolio brochure for line concepts
    Vial filling portfolio brochure for line concepts

    See Syntegon vial filling machines, formats and outputs from formulation to inspection in one overview for your next line project.

    Download
    Trend report on flexibility in vial line design
    Trend report on flexibility in vial line design

    Learn how to increase vial line flexibility, cut changeover and cleaning losses, and prepare for Annex 1 compliant production.

    Download
    IDT Biologika high speed vial filling line case study
    IDT Biologika high speed vial filling line case study

    See how IDT Biologika scaled production to 80 to 100 million 2R vials per year with a high speed line, isolator and 100 % IPC.

    Download
    Alcami small batch flexible vial filling line case study
    Alcami small batch flexible vial filling line case study

    Learn how Alcami doubled daily small batch vial capacity with a turnkey isolator line that handles 2 to 50 ml formats and lyophilization.

    Download
    Aspen Pharmacare vaccine vial line case study
    Aspen Pharmacare vaccine vial line case study

    See how Aspen Pharmacare expanded sterile vaccine vial capacity with a Syntegon vial filling line designed for multiple formats ensuring high quality.

    Download
    AJ Vaccines Case Study
    AJ Vaccines Case Study

    Learn how AJ Vaccines future-proofed its line with a RABS-update from Syntegon.

    Download

    Frequently asked questions

    Syntegon vial filling machines and vial filling lines typically cover vial volumes from 2 to 500 ml. You can run small clinical batches and large commercial batches on the same aseptic vial filling platform, with format parts and transport systems designed for gentle handling. 

    Yes. Syntegon designs complete vial filling lines from formulation and pretreatment through sterilization, filling and closing, freeze drying and inspection. Fillers, vial filling isolators or RABS, freeze dryers and inspection systems use standardized interfaces and one automation philosophy.

    This helps reduce risky interfaces and is designed to help you meet Annex 1 focused contamination control needs. 

    The pharmaceutical vial filling machines are ready for isolator or RABS integration and feature hygienic design, CIP/SIP capability and options for integrated PUPSIT filter test racks. 100% in process control and inline inspection concepts help monitor each vial and support Annex 1 focused contamination control and documentation.

    Designs aim to keep operator intervention low so you can combine sterility assurance with flexible operation. 

    Download portfolio overview

    In many cases, yes. Syntegon focuses on modular vial filling equipment and standardized interfaces, so you can add barrier systems, Telstar freeze dryers or new filling technologies later without rebuilding the entire line.

    Retrofittable PUPSIT racks, single use fluid paths and digital upgrades can also increase flexibility and reduce downtime. Concrete upgrade options depend on line age and configuration. 

    Find out more

    Syntegon aseptic vial filling equipment supports multiple systems, including rotary valve piston pumps, time pressure filling, peristaltic pumps, mass flow and rolling diaphragm pumps.

    You can combine stainless steel multi use paths with single use assemblies where they add value. This helps you process liquid, lyophilized, oily and highly viscous products on one flexible vial filling platform.

    Find out more
    Interested in vial filling machines?

    Interested in vial filling machines?

    Talk to a Syntegon expert to learn more about vial filling machines.

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    News

    Syntegon Expands OSD Pharma Process Services
    Syntegon Expands OSD Pharma Process Services

    Discover how Dr. Barbara Fretter and Syntegon enhance OSD production reliability through expert process development from the very start.

    Learn more
    New AIM9: cocreation for flexible inspection
    New AIM9: cocreation for flexible inspection

    Discover how Syntegon's experience and innovative co-creation enhance inspection machines, as explained by mechanical design engineer Sebastian Fischer.

    Learn more
    PDA James P. Agalloco Award for Markus Heinz
    PDA James P. Agalloco Award for Markus Heinz

    Markus Heinz receives the PDA James P. Agalloco Award, recognizing excellence in pharma education and cross-industry collaboration.

    Learn more