UDS Rotary Vial Filling & Assembly Workstation


The UDS Rotary Vial Filling & Assembly Workstation is an assembly and vial filling machine for unidose liquid nasal devices. Available in automatic or semi-automatic setups, it increases both throughput and flexibility through its broad array of station separation and inspection options.


For automatic operation, a racetrack format with vibratory product feeding affords speeds up to 80 to 100 pieces per minute. For semi-automatic settings, the system utilizes an operator-loaded indexing star wheel with pucks, producing up to 30 pieces per minute. After using an air jet and vacuum system to clean each vial, the machine's initial inspection station checks for cracks. To perform this step, vials are raised and rotated, allowing for 360-deg. high-resolution camera inspection.


Next, vials are filled via a precision valve-less ceramic piston filler at a station incorporating a no container/no fill sensor. A stopper is then inserted using a pick-and-place module featuring a burping tube to allow air escape during placement. Next, nasal actuators are introduced either via a secondary starwheel (semi-automatic version) or in-line via pick and place (automatic). In either setup, the actuators are inspected to make sure cannulae are present and straight, then automatically placed around the vials, which are pressed into place with an automatic tamping device. Finally, the machine ejects finished unidose delivery systems into a collection bin.


The machine is both precise and flexible. Stopper position can be determined down to 0.01 in. (0.3 mm), ensuring device specifications are met. To bolster sterility, the unit’s product contact parts are composed of ceramic, stainless, and Teflon. It is controlled via a 7 in. touchscreen HMI with recipe control and the ability to turn on or off any station or inspection as required.


  • PLC machine controller (Allen Bradley) 
  • Stainless steel vibratory bowl feeders
  • Linear servo indexing conveyor system (Versitrack)
  • Starwheel for indexing (Workstation)
  • Ethernet capabilities for remote diagnostics (option on Workstation model) 
  • Liquid filling accuracy +/- 0.5%
  • Suitable for aseptic environments
  • Compact footprint
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