The Automatic Inner-Plug Inserting Machine engineered by Siddhivinayak Engineering is a high-precision inline packaging system designed for the automated sorting, accurate placement, and secure press-fitting of orifice reducers, dropper tips, and inner plugs into diverse container formats. Utilizing a synchronized vibratory bowl feeder and precision delivery chute, the system aligns plugs before a pneumatic or mechanical pressing head seats them flush and secure into the bottle neck. Equipped with advanced optical missing-plug sensors and a “”””No Bottle – No Plug”””” safety interlock, it guarantees 100% quality verification, eliminates misaligned inserts, and prevents line jams.
Fabricated with a heavy-duty SS 304 structural framework and cGMP-compliant SS 316 contact parts, this reliable automated solution ensures flawless insertion integrity and high-throughput production for pharmaceutical eye drops, essential oils, cosmetic serums, and chemical packaging lines.
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Specification of Automatic Inner-Plug Inserting Machine
| Model NO. | SVIPC |
| Cap Size* | 25-40 mm Dia. |
| Inner pLug Size* | 22-38 mm Dia. |
| No. of Head** | 1/ Multi Head |
| Speed** | 20-100 |
| Direction | Left to right |
| Power Supply | 1 Phase 220V. AC supply |
| Air supply | 6-8 bar Air Pressure |
| * With Help of Change parts | |
| ** Customisation is possible. | |
Salient Features of Automatic Inner-Plug Inserting Machine
- Automated Plug Insertion: Automatically sorts, places, and press-fits orifice reducers and dropper tips into container necks at high speeds.
- Vibratory Bowl Feeding: Efficiently orients and feeds bulk inner plugs into the insertion station via a dedicated vibrating bowl feeder.
- Precision Pressing Head: Pneumatic or mechanical insertion punches seat plugs flush and secure without deforming container openings.
- No Bottle – No Plug Interlock: Optical sensors detect incoming containers to halt plug release when no bottle is present, preventing jams and waste.
- Optical Missing-Plug Detection: Advanced photo-optic sensors verify plug presence in every single container to ensure 100% quality assurance.
- SS 304 Main Framework: Fabricated with heavy-duty stainless steel for long-term structural durability and washdown corrosion resistance.
- cGMP-Compliant Contact Parts: Product contact components are built using high-grade SS 316 to meet strict pharmaceutical sanitary standards.
- PLC & HMI Touchscreen Control: Centralized digital interface allows easy parameter adjustments, speed monitoring, and operational diagnostics.
- Rapid Toolless Changeover: Modular starwheels and quick-release insertion tooling minimize downtime during format transitions.
- High-Speed Operational Output: Delivers high-throughput insertion performance to completely eliminate manual assembly bottlenecks.
- Adjustable Insertion Depth: Fine-tuned mechanical depth control ensures plugs sit flat, even, and leak-proof inside the bottle neck.
- Pneumatic Actuation Precision: Reliable pneumatic cylinders deliver smooth, repeatable downward pressure cycles for consistent seating.
- Safety Interlock Enclosure: Transparent polycarbonate safety guards feature door interlocks that halt operation immediately if opened.
- Seamless Line Integration: Connects smoothly with upstream liquid fillers and downstream capping or sealing machines.
Optional Features of Automatic Inner-Plug Inserting Machine
- Bulk Hopper Elevator System: Floor-level stainless steel hopper with a flighted belt elevator that automatically feeds bulk inner plugs into the primary orienting bowl feeder without manual intervention.
- Acoustic Enclosures for Feeder Bowls: Sound-insulating clear polycarbonate or SS 304 covers that fit over vibratory sorting bowls to significantly reduce ambient shop-floor noise levels.
- Ionized Air De-Static / Dust Removal Unit: In-line anti-static air blowers and dust extraction manifolds mounted along delivery chutes to eliminate static cling and airborne micro-particles prior to insertion.
- Servo-Driven Pressing Head: Replaces standard pneumatic cylinders with digital servo actuators to deliver programmable press-fit depth, real-time insertion force monitoring, and gentle handling for fragile containers.
- Dual-Head / High-Speed Insertion Module: Multi-head mechanical or pneumatic configuration designed to double production throughput for high-speed pharmaceutical and cosmetic lines.
- Advanced Vision Inspection System: High-resolution optical cameras to detect cocked plugs, partially seated plugs, upside-down plugs, or damaged orifice tips.
- Multi-Lane Classified Rejection Module: Dual-lane pneumatic air-blast system that separates containers missing plugs from those with alignment defects into distinct, secure lockable bins.
- ""No Bottle – No Plug"" Advanced Sensor Suite: Enhanced fiber-optic sensing arrays that verify bottle positioning and container neck integrity before triggering insertion.
- 21 CFR Part 11 Audit Trail Software: Upgraded control packages featuring multi-level user authentication, electronic batch reporting, and secure audit trail logging for strict pharmaceutical compliance.
- Motorized Head Height Adjustment: Push-button electric elevation mechanism for raising or lowering the insertion head assembly during quick changeovers between different bottle heights.
- Cleanroom & Construction Upgrades Full Stainless Steel 316 / 316L Contact Parts: Complete upgrade of all starwheels, chutes, guide rails, and insertion punches to SS 316/316L for corrosive chemical or pharmaceutical cleanroom environments.
Product Also Known As of Automatic Inner-Plug Inserting Machine
- Automatic carton sealing (Tape Type)
- Hot Melt Glue Sealing System
- Robotic Pick & Place Loading
- Vision Inspection System
- Barcode Verification
- Automatic Divider / Leaflet Inserter
- Reject Conveyor System
- Production Data Logging & SCADA
- Remote Diagnostics
- CE Safety Compliance
Machine Operation Process of Automatic Inner-Plug Inserting Machine
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Step 1
Container Infeed & Indexing : Containers are fed via an infeed conveyor into the starwheel indexing system, where optical sensors verify bottle presence before the insertion zone. -
Step 2
Plug Sorting & Orientation : Bulk inner plugs, dropper tips, or orifice reducers are loaded into a vibratory bowl feeder, where they are oriented single-file down a delivery chute. -
Step 3
Precision Press-Fitting :A synchronized pneumatic or mechanical insertion punch seats the inner plug flush, securely, and evenly into the neck of the container.
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Step 4
Inline Quality Inspection :Advanced photo-optic sensors or vision cameras inspect every container to verify 100% plug presence and correct insertion depth. -
Step 5
Discharge & Defect Rejection : Compliant containers are discharged toward downstream capping equipment, while any bottles missing plugs or exhibiting improper seating are automatically diverted to a reject bin.
Video of Automatic Inner-Plug Inserting Machine
Frequently Asked Questions
The machine accommodates a wide variety of container materials—including glass, HDPE, PET, and PP—alongside diverse closure inserts such as standard dropper tips, nasal spray plugs, drip reducers, and snap-in plastic stoppers for bottle sizes ranging from 5 ml to 500 ml+.
The machine is engineered with a modular, toolless changeover architecture. Operators can rapidly swap starwheels, guide rails, and insertion punches using quick-release levers, while updating operational parameters instantly via pre-saved recipes on the touchscreen HMI.
It automatically inserts and presses inner plugs, droppers, seal plugs, or press‑fit inserts into bottles with high accuracy, used in pharma, cosmetics, FMCG, food, agro‑chemicals, and beverages industries.
Machines support:
Inner plugs
Dropper plugs
Seal plugs
Press‑fit inserts
Change parts depend on container and plug size:
Star wheel
Back guide
Feed worm
Delivery chute
Bowl inserts
