1. Customer Overview

Ingal Biotechnology Co., Ltd. is a qualified pharmaceutical manufacturer in Moscow, Russia, equipped with ISO 7 clean workshops. It focuses on vial-packed liquid skincare and disinfection products, supplying local pharmacies and medical aesthetic institutions, and exporting to Central Asia. Its original segmented filling equipment with low capacity, poor precision and low automation could no longer meet mass production demands, requiring an integrated production line upgrade.

Contact Person: Vladimir Petrov, Technical Director

Cooperation Timeline: Contract signed in March 2026, equipment inspected in June 2026, official production launched in July 2026

Equipment Purchased: Fully automatic integrated vial filling line, including automatic bottle feeder, high-precision liquid filling machine, online coding machine and vertical round bottle labeling machine

2. Production Pain Points

The customer’s old standalone equipment operated independently without linkage or buffer functions, restricting mass production and compliance. Heavy manual operation caused vial damage and cleanliness problems with high labor costs. Disconnected procedures led to semi-finished product accumulation, with a low hourly output of 1,200 bottles. Traditional filling equipment featured large errors, high material waste and high defective rates, failing local quality standards. Switching between 5ml and 10ml vials required full-line shutdowns, resulting in low production flexibility. Separate coding and labeling caused traceability risks, while European imported equipment was overpriced with long spare parts delivery cycles.

3. Customized Integrated Solutions

Tailored to ISO 7 clean workshop standards, dual-specification production and Russian traceability regulations, our seamless linked production line supports independent start-stop of each device, adapting to both mass production and flexible small-batch switching:

Automatic Bottle Feeder

Built with full stainless steel for clean workshop application, it is corrosion-resistant and easy to clean. The variable-frequency sorting system automatically arranges and feeds vials and supports one-click switching between 5ml and 10ml sizes, eliminating unstable manual feeding and reducing on-site labor to only one operator per shift.

High-Precision Liquid Filling Machine

All liquid contact parts adopt 316L medical-grade stainless steel. Equipped with imported peristaltic pumps, it controls filling errors within ±1% to minimize material loss. Submerged anti-bubble filling and intelligent no-bottle no-filling functions avoid liquid leakage and underfilling. Dual-specification parameters can be switched quickly without equipment disassembly.

Online Synchronous Coding Machine

Fully linked to the production line, it automatically prints batch numbers, production dates, expiry dates and traceability codes. Photoelectric induction effectively prevents missing or incorrect coding. High-adhesion coding is fully synchronized with filling procedures, eliminating batch confusion and compliance risks from the source.

Automatic Vertical Labeling Machine

Adopting servo precise control, it adapts to various vial labels and avoids common defects such as wrinkles, bubbles and edge warping. The built-in intelligent rejection system ensures 100% labeling qualification. Seamlessly connected with the coding process, the whole labeling procedure runs fully automatically without manual intervention.

Complete After-Sales Support

The production line is equipped with a full Russian touchscreen system, complete operation manuals and tutorial videos. Energy-saving and low-noise equipment supports 24-hour continuous production with full safety protection devices. Free vulnerable spare parts are provided to solve long-term overseas maintenance problems.

4. Customer On-Site Inspection & Factory Test

To avoid overseas installation risks, the customer’s core technical team traveled to China for full equipment verification and acceptance. We completed pre-assembly, precision calibration and cleanliness treatment to build a simulated production line. The customer strictly inspected our production qualifications, material standards and electrical configurations to confirm full compliance with contract requirements.

With self-provided vials, materials and labels, the customer supervised four core tests: continuous no-load operation, full-load mass production, specification switching and fault simulation. The equipment operated stably for 4 hours with filling errors below 1% and zero defective products. We optimized system programs and operation interfaces on-site, and provided hands-on training for equipment operation, parameter adjustment, daily maintenance and troubleshooting. The customer fully recognized the equipment performance and signed the official factory acceptance document.

5. Project Implementation Timeline

1. February 2026: Online communication and customized solution confirmation; 2. Late February 2026: Production line layout design and official quotation delivered; 3. March 2026: On-site inspection and formal contract signing; 4. March – June 2026: Equipment production, program development and overall debugging; 5. Late June 2026: Final factory inspection and export packaging; 6. July 2026: Equipment put into official production after passing 72-hour continuous operation test.

6. Quantitative Project Achievements

1. Capacity upgraded from 1,200 BPH to 3,600 BPH, fully meeting peak-season bulk order demands; 2. Labor cost greatly reduced, with operators per shift decreased from 6 to 2; 3. Filling precision improved significantly, reducing material loss and defective rate; 4. Equipment utilization and production flexibility enhanced with fast specification switching; 5. Full production procedures comply with local cleanliness and traceability standards with zero compliance risks.

7. Authentic Customer Testimonial

Vladimir Petrov, Technical Director of Ingal Biotechnology Co., Ltd.

“We have compared many European equipment brands with high prices and unreliable after-sales service. We found this manufacturer through Google and came to China for on-site inspection and production tests to verify the equipment performance in person. The customized buffer accumulation system is the most satisfactory function, which completely solves our long-standing problem of full-line shutdown during specification switching. The full line features high precision, stable operation and simple operation with perfect adaptation to the Russian operating system. The professional on-site installation and training support ensures almost zero-fault operation after production. The greatly improved production capacity and yield have effectively reduced our production costs. We will maintain long-term cooperation for our future capacity expansion projects.”

8. Case Summary

This fully automatic integrated vial filling production line is customized for overseas clean workshops, integrating automatic bottle feeding, filling, buffering, coding and labeling. It features high precision, high output, low material loss, flexible model switching and full compliance traceability. We provide one-stop services including customized solutions, factory inspection support, multi-language documents and localized after-sales service, fully adapting to automatic mass production of various liquid vial products.