Non‑Standard Custom Case Study: Fully‑Automatic Filling & Capping Machine for Small‑Neck Long Glass Tubes with Straw‑Equipped Caps
Project Background
Off‑the‑shelf filling and capping machines are mostly engineered for standard bottles with larger openings and higher fill volumes. They rarely work well for highly specialized packaging requirements: miniature glass vials, ultra‑narrow necks, special caps with built‑in straws, and high‑precision micro‑dose filling.
This custom GDT‑25S automatic filling‑capping monoblock was built by Migrand Machinery for a client in Russia. It is a high‑difficulty non‑standard automation solution for slender miniature glass tubes. The machine meets overseas export requirements, strict dosing accuracy and stable continuous‑run production standards.
Client Packaging Specifications
Glass vial: Height 43.97 mm, neck diameter only 7.43 mm, body diameter 8.88 mm (slender miniature glass tube vial)
Matching cap: Special cap with integrated long straw; cap length 37.3 mm
Filling requirement: Target fill weight 0.8 g, allowable tolerance ±0.05 g (filling range: 0.75‑0.85 g)
Material: General free‑flowing liquid
Target output: 15‑22 bottles per minute
Export requirements: 220V 1P 50Hz power supply, EAC marking on nameplate, translated user manual for Russian‑speaking markets
Core Technical Challenges of the Project
Ultra‑small neck and complex special packaging
The vial neck is merely 7.43 mm, paired with special caps fitted with long built‑in straws. Conventional cap sorting and capping mechanisms easily trigger cap misalignment, bent straws and positioning errors. Thin‑walled small glass tubes are prone to tipping and cracking during conveying, which demands highly customized fixtures, positioning stations and dual vibratory feeder structures.
High‑precision micro‑dose filling
At a fill weight as low as 0.8 g, dripping, residual liquid and peristaltic pump pulsation can quickly push dosing outside tolerance. Fine servo‑aided tuning of the peristaltic pumping system is mandatory to hold ±0.05 g accuracy.
Synchronized feeding from dual vibratory feeders
Separate vibratory feeders sort and feed glass vials and straw‑fitted caps. Precise timing coordination is required between bottle feeding and cap feeding. “No bottle‑no fill” and “No bottle‑no cap” interlocks are essential to prevent waste and defective outputs.
Full‑scope overseas custom delivery
Project deliverables include EAC‑compliant nameplate, regional power configuration, branded HMI interface, translated documentation, plus complete photo‑video records from factory testing through container loading for client acceptance.
Customized Machine Solution
To resolve above pain points, Migrand Machinery adopted a rotary turntable layout. The control system combines Delta PLC and servo drives, paired with Kunlun HMI. Sensors are selected from Keyence / Panasonic / Leuze. All pneumatic components are Airtac. Dosing is handled by high‑quality domestic peristaltic pumps. Two spare pump hoses are supplied as wearing parts. Indexing cam divider and stepper motors use proven domestic components to balance stable performance and convenient aftermarket support for overseas end users.
Micro‑dose peristaltic filling systemThe peristaltic pump delivers stable 0.8 g dosing with ±0.05 g accuracy. Filling nozzle travel height is optimized for the 7.43 mm narrow neck to minimize liquid splashing and dripping, compatible with client‑specified free‑flowing liquids.
Dual independent vibratory feeding systemDedicated vibratory feeders handle glass tubes and straw‑equipped caps separately. Built‑in electrical interlocks for no bottle no filling and no bottle no capping. When no vial is detected, filling and capping stations skip operation automatically to cut material loss and defect rates.
Custom tooling and capping stationCustom‑built vial seating fixtures and capping heads are engineered for thin‑walled miniature glass tubes and straw‑integrated caps. Capping pressure is adjustable via parameters to avoid bent straws, tilted caps and glass cracking. Finished vials are collected by gravity chute.
Electrical & Component List
Component
Brand Selection
Human‑Machine Interface
Kunlun Touchscreen
PLC, Expansion Module, Servo Drive
Delta
Fiber Optic & Photoelectric Sensors
Keyence / Panasonic / Leuze
Pneumatic Components
Airtac
Peristaltic Pump, Cam Indexer, Stepper Motor
Premium domestic brands
Supplied Wearing Spares
2 pcs peristaltic pump hoses
Export‑oriented Customization
Power supply: Single‑phase 220V, 50 Hz for Russian grid standards
Nameplate: Machine nameplate marked with EAC certification logo
Documentation: Translated operation manual; HMI supports custom client logo upload
Factory acceptance protocol: Full‑set original photos and videos including running machine footage, station close‑ups, electric cabinet samples, finished product samples, wooden crate packaging, fumigation marks, shipping marks and container sealing records, delivered for client factory acceptance.
Machine Performance Specification Sheet
Item
Specification
Model
GDT‑25S Custom Filling & Capping Monoblock
Applicable Vial
Slender glass tube vial, neck φ7.43 mm, height 43.97 mm
EAC / CE marking, translated manual for Russian & Europe market
Project Conclusion
This GDT‑25S custom filling‑capping unit built by Migrand Machinery demonstrates that non‑standard automation can deliver full‑line automatic production including bottle sorting, filling, cap feeding, capping and finished‑product discharge, where standard off‑the‑shelf bottling machines cannot handle odd‑shaped packaging or strict micro‑dose accuracy.
This solution fits applications including miniature glass tube vials, products using caps with built‑in straws, low‑volume liquid bottling, and export projects requiring EAC certification.If you face challenges such as extra‑small bottle necks, special non‑standard caps or tight‑tolerance low‑dose filling and cannot find suitable standard equipment, send us your packaging samples and process requirements. Migrand Machinery can evaluate and develop tailor‑made automatic monoblock filling and capping solutions for your production.
On the basis of more than 20 years of manufacturing technology, we always adhere to the principle of customer first, do every detail work in the spirit of craftsmanship, and provide the most timely and effective after-sales service.
Grand Packing Machinery is a professional system integrator for packaging production lines and a provider of import and export services.
