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    Vial filling machines

    One line. Any vial. Maximum flexibility.

    Simplify and future-proof your production with vial filling equipment that adapt to you. Whether you’re facing regulatory pressures or evolving market needs in terms of batch sizes and formats, we provide the speed, flexibility, and compliance you need, without sacrificing efficiency.

    Syntegon’s vial filling and sealing machines are engineered for maximum adaptability, enabling rapid format changes and multi-product processing. To make your (re-)validation simpler, we offer end-to-end, seamlessly integrated lines, including isolator, freeze-drying, and inspection solutions.

    Over 1,500 vial filling lines installed at CDMOs, pharmaceutical and biotech companies around the world are proof that our solutions are engineered to deliver long-term reliability, seamless integration, and full regulatory readiness.

    Contact our experts to find the right solution for your production goals.

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    Solving your vial filling challenges

    Whether you're preparing for Annex 1, scaling up capacity, or handling high-potent products – our solutions help you reduce complexity, downtime, and risk. Your requirements are unique, and we structure our technology and services around the challenges that matter most to you:

    Combining flexibility and speed
    Combining flexibility and speed

    Matching a variety of market needs from micro to high quantity batches with varying volumes can be a challenge, especially on a tight timeline. Our solutions feature quick, tool-less changeovers, process a wide range of vial formats and volumes and help you adapt faster without sacrificing efficiency.

    ✓ Tool-less changeovers
    ✓ Vial range from 2 to 500 ml
    ✓ Modular design for scaling output

    Safeguarding regulatory compliance
    Safeguarding regulatory compliance

    With the growing complexity of global regulations, including Annex 1, compliance needs to be built into your line from day one. Our vial filling machines enable compliance with isolator compatibility, cleanability (CIP/SIP), and integrated 100% IPC.

    ✓ Isolator, oRABS, cRABS integration
    ✓ Inline inspection and 100% IPC
    ✓ Designed for no or little operator intervention

    Adapting to different dosage needs
    Adapting to different dosage needs

    Vial filling isn’t one size fits all. Different products require different handling, dosing, and contamination strategies. Our systems are designed for maximum flexibility, so you can fill what your market demands – now, and in the future.

    ✓ Liquid, lyophilized, oily, or viscous product
    ✓ Freeze-dryer and inspection integration
    ✓ From small batch to high-output commercial filling

    Explore our complete vial filling portfolio

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    Format-ready solutions

    If you need flexible batch sizes and format agility: 

    • Ideal for early-phase, CDMO, or multi-product facilities
    • Fill anything from 2–500 mL with minimal format part changes
    • Rapid, tool-less changeovers across formats and vial types

    Best for: Agile production environments scaling from R&D to commercial.

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    Integrated line solutions

    If you're building or upgrading a full line:

    • Combine vial filling with isolators, freeze-dryers, inspection, and automation — all from one partner
    • Synchronized controls and line validation save time and cost
    • Optimized for Annex 1 and GMP compliance

    Best for: Facilities building new lines or modernizing legacy assets.

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    High-potency & aseptic solutions

    If you're handling complex or high-risk drugs:

    • Supports toxic, viscous, sensitive or lyophilized products
    • Closed systems: isolator, oRABS, cRABS compatibility
    • Built-in 100% IPC, in-line inspection, and minimal operator contact

    Best for: Oncology, biologics, CGT, and risk-critical pharma lines.

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    Whether you're scaling early-phase production, upgrading a legacy line, or filling sensitive high-potency drugs — our experts can help you find the right solution. Download the full vial filling portfolio to explore machine specs, use cases, and integration options. Or get in touch directly to discuss your specific requirements — from batch size and product type to regulatory or site constraints.

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    Design your optimal vial filling line

    Explore configuration options and discover how Syntegon technology adapts seamlessly to your production needs – from small batches to commercial scale.

     
    Connect with our experts

    Your benefits with our vial filling solutions

    Our vial filling solutions are designed to meet your specific needs, whether you’re producing large commercial batches or handling multiple small-scale formats. From aseptic vial filling to isolator integration, freeze-drying and inspection – Syntegon offers seamless, end-to-end systems that ensure product safety, compliance, and long-term performance. Our portfolio is modular, scalable, and built for Annex 1-readiness from day one.

    Aseptic filling meets efficiency

    100% in process control ensures consistent product safety. With up to 600 vials filled per minute, you don’t need to compromise on efficiency.

    process-control

    Purified media are a prerequisite for processing and producing liquid pharmaceuticals. Our portfolio includes both distillation and cold membrane processes for WFI, as well as thermal generation solutions for WFI and pure steam. Of course, we also offer you a well-designed system concept for the storage and distribution of PW and WFI.
    Our formulation systems, in turn, support you in producing the actual solutions. From preparation and filtration to centrifugation and chromatography – ask our experts and they will be sure to propose the right solution for your products.

    Benefits:

    • Generation, storage, and distribution of pure media
    • New: cold membrane process (MWFI)
    • Formulation systems for multiple process steps
    Our formulation system
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    Proven in practice: How pharma leaders use our vial filling solutions

    Leading pharma companies and CDMOs trust Syntegon to help them scale, comply, and adapt. Here’s how:

    IDT Biologika: built for scale, speed, and flexibility

    IDT Biologika: built for scale, speed, and flexibility

    CMOs need to scale up capacity quickly when customers need it. Discover how German company IDT Biologika boosted output as well as flexibility – with one of the world’s fastest vial filling lines featuring full in-process control from Syntegon.

    The result: faster changeovers and up to 100 million vials filled annually.

    Download case study
    Alcami: fully integrated line concept

    Alcami: fully integrated line concept

    US-based CDMO Alcami needed to expand its vial filling capacity to meet growing demand and format flexibility. Syntegon provided a turnkey line with isolator and lyophilization technology, enabling faster product changeovers and higher output.

    The result: fully integrated line with over 6,000 vials per hour filled – more than doubled daily output.

    Download case study
    Aspen: flexible, fast, and ready for every opportunity

    Aspen: flexible, fast, and ready for every opportunity

    For South African pharma manufacturer Aspen, Covid-19 proved a chance as well as a challenge. Thanks to Syntegon retrofitting a fully integrated isolator line, Aspen was able to pivot to vaccine production before its competition.

    The result: ready for 24/7 vaccine manufacture in under 6 months.

    Download case study
    AJ Vaccines: Annex 1-ready with seamless line upgrade

    AJ Vaccines: Annex 1-ready with seamless line upgrade

    Buying a new machine or upgrading existing equipment to be ready for Annex 1? Learn how Danish pharmaceutical manufacturer AJ Vaccines answered this question and future-proofed its vial filling operations with help from Syntegon and a RABS-update on an existing machine.

    The result: Annex 1-ready with existing equipment.

    Download case study

    Looking for the right vial filling solution?

    Discover tailored, efficient solutions designed to meet your specific business requirements—backed by our industry expertise and innovative technologies.

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    Our solutions for vial liquid filling -> This section will be moved to the subsites

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    FLC 3000

    The FLC 3000 has set trends and delivered proof in many customer applications: its unique combination of flexibility and compact design have made it the preferred choice for safe and efficient filling and closing of vials and infusion bottles in the medium and high output range: 600 vials per minute are possible with a filling range of 0.2 to 500 milliliters. This is achieved with only three format part sets and minimal changeover times. No pharmaceutical filler was built as often as the FLC – with more than 650 installations worldwide.

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    ALF 5000

    Three different versions for high-output production: this sums up what the ALF 5000 has in store for you. The latest generation of the proven ALF series of filling and closing machines achieves high outputs of up to 36,000 vials or ampoules per hour, or both on the combi platform. The next level pharmaceutical design and remarkable accessibility make the ALF 5000 a benchmark in the mid and high-performance range. Hygienic operations are another mainstay, as the easy-to-clean machine shows a lower contamination tendency. It further features an optional 100 % in-process control (IPC) at constant speeds – up to 600 vials per minute.

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    MLF 3000

    The MLF 3000 filling and closing machine for vials and infusion bottles combines medium output with the highest flexibility. Its modular design and large processing range from 2 to 500 milliliters make it ideally suited for versatile applications. You can achieve output rates up to 200 containers per minute. Monoblock versions including crimping are also available, still featuring a small footprint.

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    Versynta ARF 1000

    If you are looking for a flexible filling and closing machine for industrial small-scale production and studies of pharmaceutical liquids in vials, our ARF 1000 is the right choice. The intermittent, rotary machine achieves an output of up to 7,200 containers per hour. You receive the highest flexibility and efficiency combined with a small footprint. The optional 100 % in-process control (IPC) adds to safe and reliable results. We also offer a monobloc version with integrated or separated capping including inline inspection systems. And for everyone looking for even more flexibility: the ARF is also available as a combi machine for vials and ampoules in the smallest space.

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    Each question should be phrased naturally, reflecting real decision-making concerns rather than generic inquiries. The answers should be clear, direct, and actionable, ensuring that users quickly get the information they need. Where relevant, link to more detailed resources or service offerings to guide users toward deeper engagement. Keep responses concise and easy to scan, focusing on what matters most to the decision-making process. This section ist not an SEO afterthought.

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    Each question should be phrased naturally, reflecting real decision-making concerns rather than generic inquiries. The answers should be clear, direct, and actionable, ensuring that users quickly get the information they need. Where relevant, link to more detailed resources or service offerings to guide users toward deeper engagement. Keep responses concise and easy to scan, focusing on what matters most to the decision-making process. This section ist not an SEO afterthought.

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    Looking for more ways to optimize your operations? Explore our comprehensive service portfolio to see how Syntegon’s expertise can support your success. Whether you need tailored Service Agreements, Expert Services, or ongoing support, we’re here to help. Discover how we can work together to achieve your goals.

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    Your vial filling resources – all in one place

    From line overviews to future trends, get the insights that support your next decision.

    Explore the complete vial liquid filling portfolio 
    Explore the complete vial liquid filling portfolio 

    Discover our vial filling solutions, tailored to meet diverse output, batch size, filling volume, and dosage form needs. 

    Download
    Learn how to master flexibility in vial line design
    Learn how to master flexibility in vial line design

    Our trend report will give you expert insights on how to boost your line’s flexibility.

    Download
    Case Study IDT Biologika
    Case Study IDT Biologika

    Discover how IDT Biologika boosted output as well as flexibility – with one of the world’s fastest vial filling lines from Syntegon. 

    Download
    Case study Alcami
    Case study Alcami

    Explore how Alcami more than doubled daily output with a turnkey line from Syntegon.

    Download
    Case Study Aspen
    Case Study Aspen

    Read how Aspen was able to pivot to vaccine production quickly with a retrofit from Syntegon.

    Download
    Case Study AJ Vaccines
    Case Study AJ Vaccines

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

    Download
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