Neocarton-Your Reliable Vial Cartoning Machine Manufacturer in China
The vial cartoning machine is specially for the pharmaceutical industry and packs vials into cartons at high speed, with precise and stability. The flexible drive and multi-axis servo control system reduce breakage rate and rapid changeover. The hygienic cleanroom-compatible design and audit trail functions help you pass FDA 21 CFR Part 11 compliance.
The visual inspection and intelligent elimination system prevents machine jams and missing leaflets during the high-speed production, improving your OEE. Our vial cartoning machines are used in large-scale vaccine production, multi-specification clinical samples, and high-end medical beauty products. We customize an integrated vial packaging solution that complies with GMP standards for you.
Our Products
Its compact structure makes it easy to switch to produce pharmaceutical packaging in multiple specifications, which is an ideal choice for pharmaceutical enterprises focusing on space utilization.
The machine operates continuously at high speed to pack large-scale vaccine and injection production lines, which is a common cartoning solution for large-scale pharmaceutical factories.
It packages single-bottle products and protects fragile products like biological agents, freeze-dried powder injections from breaking, increasing the integrity of drugs.
It packages multiple vials at once and flexibly adjusts packing quantity without manual intervention or secondary sorting, providing efficient solutions for pharmaceutical packaging suppliers.
Features of Vial Cartoning Machine
Multi-axis servo optimizes curve optimization to protect fragile vials, reducing the rate of broken bottles nearly to zero, avoiding frequent shutdowns caused by damage.
Wear-resistant buffer star wheels precisely control vial spacing, avoiding collision and scratches in the high-speed line and ensuring complete labels.
The multi-axis linkage feeds fast switching vials from 2ml to 50ml and is ideal for pharmaceutical packaging suppliers handling multiple SKUs.
For expensive space costs in pharmaceutical enterprises, the compact layout of the machine increases the utility rate of space while reducing the difficulty of daily cleaning and maintenance.
Zero Cross-contamination
Biological agents and drugs in vials have high value. Cross-contamination reduces the effectiveness of medicine and causes huge financial losses. Compared to common equipment, professional vial cartoning machines can operate in enclosed environments, which helps pharmaceutical packaging suppliers reduce pollution caused by packaging material debris. This avoids medicinal liquid waste caused by unqualified packaging, reducing the compliance costs of your enterprise.
Soft Landing Load
Light collision reduces the breakage rate of vials when entering the carton, and the machine easily handles vulnerable products like antitumor drugs, freeze-dried powder, etc. According to the diameters of different vials, the synchronous push rod compensates dynamically to reduce impact, and vials softly land onto the bottle of the carton. This extends the service life of the transmission components and reduces long-term operation and maintenance costs.
Applications of Vial Cartoning Machine
Vial cartoning machine precisely packages tablets and injections, reducing waste rate during distribution. The mechanical hand places instruction manuals into the carton, ensuring packaging integrity and compliance, providing a scalable production plan for pharmaceutical manufacturers.
The machine complies with cleanroom and provides an aseptic packaging environment for diagnostic reagents, pre-filled syringes, implants, and test kits. Machines with custom inner containment configurations ensure their integrity during transportation and storage.
Clinical tests use vials with multiple varieties and small batches. Vial cartoning machines for laboratory vials switch specifications within several minutes, which reduces packaging material waste and time when switching varieties, and shortens the launch time for a new drug.
Vials store high-value essence. Vial cartoning machines for the aesthetic medicine equip an inner tray and activate the anti-counterfeiting label, preventing vial surface scratches and product counterfeiting, increasing the premium of your medical beauty products.
- Specifications
| Production Speed | 30 – 120 Cartons/Minute |
| Carton Size Range | W: 20 – 150 millimeters, L: 30 – 200 millimeters, H: 15 – 100 millimeters |
| Carton Blanks | Folded cardboard, offset laminated cardboard or cold stamping paper materials |
| Vial Range | 2ml – 100ml vials with stoppers or without stoppers and caps |
| Power Requirement | Three-phase electrical system |
| Air Consumption | 0.5 – 0.8 MPa |
| Control System | PLC + HMI |
| Compliance | Compliant with GMP standards and supporting 21 CFR Part 1 |
Yes. The machine stably handles drug packaging cartons of various thicknesses ranging from 250 to 350 g/m 2. Even packaging materials have large weight fluctuations, it ensures the success rates of the suction and support, reducing downtime caused by carton quality.
The precisely adjusted folding rollers and creasing lines ensure neat edges and uniform thickness. The flattening process eliminates the leaflet rebound, preventing scratches caused by uneven instruction manuals. The servo control system ensures leaflets always maintain strict phase synchronization with vials and are precisely pushed.
By standardized PLC interface and communication protocol, our vial cartoning machines easily connect with upstream filling line, downstream vial packaging, and palletizing machine. This improves packaging continuity of the production line and ensures data completely of your products throughout their entire life cycle.
Complex machines are equipped with a remote diagnosis. Through network connection, engineers remotely diagnose faults and upgrade programs, avoiding long-term downtime to affect your production. Our overseas team provides on-site installation and employee training services, and your machines can be put into operation in a short time.
Not frequently. Key components, such as suction cups, folding blades, and synchronous belts, are made of high-quality wear-resistant materials, and their lifespan is higher than industry average. The modular replacement structure of the machine is convenient to maintain without complex tools, thereby reducing your long-term operating costs.
For high-value biological products such as vaccines and monoclonal antibodies, the machines can be equipped with automatic tray forming machines or partition insertion modules. It provides shock-proof and cushioning protection during transportation and packaging, offering your products a high-end and safe packaging solution that complies with international standards.
The machine uses anodized aluminum or 316L stainless steel materials and a dead-angle-free design, which effectively prevents dust accumulation. The inclined frame is convenient to clean and disinfect, saving you the cost of manual cleaning. The food-grade lubricating oil of the transmission system meets pharmacopoeia requirements, helping you quickly pass GMP verification.
Low energy consumption. The servo driver adopts a low-power design, reducing power consumption by approximately 20%-30% compared to traditional mechanical transmission structures. When there is a temporary material shortage, the machine will automatically enter a low-power standby state to reduce unnecessary energy loss.
How Does A Vial Cartoning Machine Work?
Vial Loading and Feeding
The conveyor belt and feeding track transports vials and the buffer star wheel gently separates and arranges vials, avoiding vial body scratches and damage. This ensures each vial enters the system steadily and orderly, preventing downtime due to crowded vials.
Cartons Preparation
The carton forming unit uses vacuum suction to pick up carton blanks and rotary opening mechanism shapes the carton to achieve stable carton opening geometry. Even slightly deformed cartons can be opened 100%, reducing the material waste during production.
Insert Vials into Cartons
According to your machine types, vials can be inserted into the carton from the side or above.
Leaflet Placement
The folded leaflet is put into the carton before sealing to comply with regulatory compliance requirements and help pharmaceutical companies obtain GMP certification and pass quality audits.
Carton Closing and Sealing
According to your requirements for medicine packaging, we offer glue or tuck-in closure. For example, The hot melt adhesive sealing prevents altering drug information, used for drugs with strict requirements for anti-counterfeiting information. The snap-on device is convenient to open and is often used for regular ointment vials.
A good seal prevents the carton from being damaged during transportation and stacking, maintaining the brand’s reputation for supply chain integrity.
How to Choose A Vial Cartoning Machine?
Machine Speed and Flexibility
The machine speed should match accuracy. High-speed machines need high-precision sensors and servo control systems to maintain precision during the folding, sealing and product insertion, avoiding jamming or wrong deliveries.
Manufacture Requirement
Choose a suitable vial cartoning machine according to your current production capacity and future expansion plans.
Small scale production: for small laboratories or start-up pharmaceutical enterprises, we recommend you choosing machines with compact structure and flexible switching.
Medium to high output: for pharmaceutical factories of commercial-scale operation and large-scale production, continuous high-speed vial cartoning machine is a good choice.
Production line expansion requirements: If your production line needs expansion in the future, choose a machine with a slightly higher capacity, avoiding repeated investment when expanding and enhancing its long-term use value.
Space Efficiency
Pharmaceutical workshops have high requirements for space utility rate. You don’t need to expand the workshop volume due to compact floor area, achieving efficient cartoning within the limited space.
Integration Requirements
The machine should match the your workshop layout and filling machines, labeling machines, inspection machines and case packing systems, which ensures stable operation of the equipment in the future and reduces integration risks.
Enough space should be reserved for maintenance personnel and operators to move around.
Total Cost of Ownership
Initial cost of the machine is important, while total cost of ownership can more accurately reflect the long-term value.
Energy efficiency: High-quality machines equip servo-driven motors and intelligent control systems, which significantly reduces energy consumption.
Maintenance and downtime time: highly stable machines reduce downtime and mean time between failures, and have a higher long-term investment value.
Operational Safety and Personnel Protection
Vial cartoning machines that complies with GMP and CE standards easily pass the international market review and help your factory avoid the work-related injury risks.
High-quality vial cartoning machines usually equip safety door interlocks, emergency stop systems, hand-protection devices and fault alarm functions to reduce operational risks and protect personnel safety.
Supplier Support
Reliable supplier support reduces downtime and ensures stable production operation. It offers on-site installation, operation training, remote diagnosis, and preventive maintenance services. It has a rapid response capability and provides long-term stable spare parts and technical support.
Customization
Not all products have regular shapes, sizes and comply with standardised cartons. As a professional vial cartoning machine supplier, we offer customization services based on the vial size, the special arrangement, and carton structure to adapt to your special packaging requirements.
Why Is Automatic Vial Cartoning Machine Important for Pharmaceutical Packaging?
Consistency
Automatic vial cartoning machine precisely controls cartoning process and ensures each carton contains vial, leaflets, and documents, avoiding missed and incorrect installation compared to human packing and maintaining long-term and stable packaging quality.
High-speed Production
High-speed automatic cartoning machine processes hundreds of cartons per minute, suitable for large-scale production of vaccines, injections and biological products. For pharmaceutical manufacturers who want to expand production capacity, automatic packaging lines significantly reduce unit production costs and enhance their market delivery capabilities.
Traceability
Modern vial cartoning machines usually integrate inkjet printing, barcode recognition and visual inspection systems, and each carton has unique identification, facilitating drug recall and batch management.
Expansibility
As your product line expands, the automatic production line can be expanded, such as adding robot packaging, automatic boxing or visual inspection modules, to accommodate different-sized vials and packaging.
