UDS Vial Filling and Assembly System – Racetrack Format
The TurboFil Production UDS Vial Filling and Assembly System – Racetrack Format is a fully automatic, production-scale solution designed for high-speed filling and assembly of single-dose nasal and unidose drug delivery devices. Built on a servo-driven racetrack-style puck conveyor, the system automates the entire process from component feeding through filling, stoppering, final assembly, labeling, and downstream transfer.
The system uses stainless steel vibratory bowl feeders and precision pick-and-place mechanisms to automatically feed and place vial holders, glass vials, pistons, and actuators into removable pucks. Each puck securely holds components as they index through cleaning, filling, inspection, and assembly stations, ensuring controlled handling and consistent positioning throughout the process.
Liquid filling is performed using a servo-driven ceramic piston pumping system, delivering high-accuracy dosing for low-viscosity, water-like products. Integrated diversion and in-line weighing allow for periodic net weight verification without interrupting production flow. Following filling, pistons are inserted using a controlled two-stage seating mechanism with a burping funnel to release trapped air and ensure precise depth placement.
The system incorporates extensive in-process inspection using vision, force, and sensor-based checks at critical stages, including vial integrity, fill height, piston placement, actuator integrity, device assembly, and labeling verification. Completed devices are automatically transferred to an integrated racetrack-style labeling conveyor, where dual servo labelers apply labels to both sides of the device, including printed lot and expiration information when required.
Designed for pharmaceutical production environments, the system supports recipe-driven operation, electronic records, and data integrity features suitable for regulated manufacturing. The modular racetrack layout allows integration with downstream equipment such as blister packaging or cartoning systems.
Features
• Fully automatic UDS vial filling and assembly system
• Racetrack-style servo indexing puck conveyor
• Automatic feeding of vial holders, vials, pistons, and actuators
• Servo-driven ceramic piston filling system
• Four or six filling nozzles, depending on speed configuration
• Air and vacuum vial cleaning station
• Two-stage piston insertion with depth control
• Automatic vial-to-vial-holder transfer and tamping
• Integrated dual-head servo labeling system
• Extensive in-process inspection and reject handling
• Recipe-driven PLC control with touchscreen HMI
• Designed for controlled and aseptic production environments
Speed
• Target production speed: up to 100 units per minute (ppm)
• Speed dependent on configuration, inspection options, and filling setup
Inspection & Quality Control Capabilities
• Vial holder bridge integrity inspection
• Glass vial body crack inspection
• Vial rim inspection prior to final assembly
• In-line fill weight verification with diversion loop
• Vision inspection for fill height, piston presence, and piston depth
• Cannula presence and straightness inspection
• Actuator placement force monitoring
• Finished device pull test for integrity
• Label presence, print verification, and OCR inspection
• Reject verification at all reject stations
Benefits
• Enables true production-scale automation for UDS devices
• Reduces manual handling and operator variability
• Ensures consistent fill accuracy and assembly quality
• Integrates inspection at every critical process step
• Supports regulatory and data integrity requirements
• Scalable platform for commercial manufacturing
• Designed for seamless downstream packaging integration