Compact Ampoule Washing Machine

Q: What is a Compact Ampoule Washing Machine?

A Compact Ampoule Washing Machine is a space-saving, high-speed, cGMP-compliant rotary washer designed for thorough internal and external cleaning of glass ampoules (1ml to 10ml / up to 20ml with change parts). Its compact footprint makes it ideal for small to medium-scale injectable manufacturing units, R&D labs, pilot plants, and facilities with limited cleanroom space. The machine uses neck-holding grippers, multiple washing stations, and independent circuits for Water for Injection (WFI), DM water, recycled water, and compressed air to ensure excellent cleaning with low breakage and minimal resource consumption.

Q: What are the available models and production capacities of the Compact Ampoule Washing Machine?

We offer two main models: AVRW 120 : Up to 100 ampoules per minute AVRW 240 : Up to 200 ampoules per minute Both models handle ampoules with diameters of 9mm to 21.5mm and heights of 60mm to 140mm. The compact design (approx. 2050mm L × 2000mm W × 1210mm H for AVRW 120) allows easy installation while maintaining high output and low breakage rate (≤ 0.5%).

Q: What utilities are required to operate the Compact Ampoule Washing Machine?

The machine requires: Power : 4 H.P. (AVRW 120) or 5.5 H.P. (AVRW 240) — 440 Volts, 3 Phase, 50 Hz (customizable as per customer requirement) Compressed Air : 20 CFM Water : 200 to 500 liters per hour (depending on ampoule size) It also features optional 3 × 25-liter water tanks with centrifugal pumps and recirculation system for reduced WFI consumption. The compact size helps lower overall installation and operational costs.

Description

A Compact Ampoule Washing Machine is a specialized pharmaceutical device designed to clean glass ampoules (1ml to 20ml) and sometimes vials (2ml to 100ml) with minimal contact to ensure sterility and compliance with cGMP standards. These machines are widely used in pharmaceutical, veterinary, and biotech industries for efficient, high-quality cleaning of small glass containers.

Compact Design: The machine features a space-saving, enclosed structure, typically made of stainless steel (SS 304 for non-contact parts, SS 316L for contact parts with wash media), ensuring durability and hygiene.

Washing Process:
- Utilizes a multi-stage cleaning process, often including ultrasonic washing, purified water wash, water for injection (WFI) wash, and compressed air blowing to remove particulate contamination (up to 3 log reduction).
- Positive and pressurized jets deliver precise cleaning with minimal water usage, ensuring both internal and external surfaces are thoroughly cleaned.
- Some models offer customizable washing sequences (e.g., 2 water and 2 air washes externally, 3 water and 4 air washes internally).

Gripper System: A specially designed gripper mechanism holds ampoules by the neck, inverts them for cleaning, and releases them in a vertical position post-washing, minimizing breakage and ensuring positive cleaning.

Automation and Control:
- Available in semi-automatic or fully automatic models, with options for PLC-based control, HMI touchscreens, or timer-operated solenoid valve systems for precise cycle management.
- Some machines feature password-protected process parameters and data logging for validation and compliance with GMP standards.

Capacity and Flexibility:
- Suitable for ampoules (1ml to 20ml) and vials (2ml to 100ml) with interchangeable change parts for different container sizes.
- Output varies by model, ranging from 30 trays/hour (semi-automatic) to high-speed models handling 100–240 ampoules per minute.

Additional Features:
- Acrylic top covers for visibility of the washing process.
- Low bottle breakage rate (≤0.5%).
- Emergency stop buttons, safety interlocks (e.g., stops if cover is lifted), and vacuum insulation for motor protection.
- Some models include drying cycles with adjustable temperature settings.

Compliance and Materials:
- Designed to meet cGMP and ISO 14644-1 standards, ensuring an ISO 5 clean environment.
- Contact parts are made of FDA-approved materials like SS 316L, silicone, or polycarbonate to prevent contamination.

Salient Features of Compact Ampoule Washing Machine

Complete cGMP model.
Production output capacity up to 200 ampoules per minute.
All contact parts with the internal surface of Container and the wash media are made from AISI 316L Stainless Steel.
Non-contact parts are made from engineering plastic, AISI SS 304 materials.
All finishes, welding joints are processed, treated & equipment selected in accordance with cGMP standards.
Machine provides 3 water washes & 3 Air washes.
Complete flexibility with user for washing cycle.
18 Jets for 6 internal washing zones.
15 Cassette of Grippers each having 2 Grippers.
Suitable for 1ml to 10ml ampoules.

Washing sequence can be adjusted as per customer’s requirements.
3 Pumps and 3 Tanks of 25 liters each. (Optional)
Each washing zone with independent circuit to avoid contamination.
Automatic Infeed and Exit of containers.
Machine is equipped with PLC system & printing facility with passwords. (Optional)
Container unit counter with display in the control panel
Machine can use as a sole machine or inline.
Digital speed indicator for current output
IQ/OQ/DQ validation documentation can be provided.
Programming and software validation as per 21 CFR Part 11 can be done on demand.

Working Principle of Compact Ampoule Washing Machine

Ampoules feed from the Infeed tray are received on an Infeed Feed worm then moves on Infeed starwheel. The Grippers picks up the Ampoule from Infeed Star Wheel and invert it in neck down position over washing needles and move along with the needle bar for Washing. Ampoules traveling in neck down position above washing needles and moves along with the Needle bar ensures maximum time for washing once the needle enter in the Ampoule neck. Machine having six different washing stations each of 6 needles for optimum Washing and the sequence can be adjusted as per requirements. Washer also having external wash for optimum washing of ampoules.

On completion of a cycle, washed Ampoules are again inverted to neck upward position and feed to output star wheel. Washed Ampoules received from output starwheel can be collected on Output Tray or can be pushed to tunnel. A separate pumping station (optional) gives the right quantum of water at the desired pressure. In the absent of separate pumping station, we can provide the re-circulation & siliconization system on request.

INTERNAL CLEANING:

The AVRW is equipped with 6 internal cleaning stations and each station has 6 cleaning needles making up a total of 36 cleaning needles. Each cleaning station is supplied via a pipe connected to the cleaning media-making washing area. This not only reduces the risk of particle generation, but also simplifies maintenance and cleaning efforts while saving time.

EXTERNAL CLEANING

The 3 external cleaning stations mounted in a stationary position above the ampoule can be easily adjusted for a specific height, angle and lateral position. Each cleaning station receives cleaning media-making through a pipe connected to the cleaning media-making washing area.

CLEANING MEDIA PRINCIPAL:

WFI, Purified water and air cleaning station are synchronized with the ampoule by reciprocating motion. Design is such that these media are put to use only when needles motion in forward direction. WFI consumption is further reduced by collecting the WFI in re-circulating water tank to be used later on in the pre-washing station.

Technical Specification of Compact Ampoule Washing Machine

Model	AVRW 120	AVRW 240
Production Output	Up to 100 per minute	Up to 200 per minute
Ampoule Diameter	9mm to 21.5mm	9mm to 21.5mm
Ampoule Height	60mm to 140mm	60mm to 140mm
Power Load	4 H.P.	5.5 H.P.
Power Voltage	440 Volts, 3 Phase 50 Hertz, 4 wire system	440 Volts, 3 Phase 50 Hertz, 4 wire system.
Optional Accessories	Programmable Logic Control (System) with HMI Safety Cabinet with doors	Programmable Logic Control (System) with HMI Safety Cabinet with doors
Utility	Air – 20 CFM Water – 200 to 500 liters per hour depend upon ampoule size.	Air – 20 CFM Water – 200 to 500 liters per hour depend upon ampoule size.
Water Tank & Pump	3 nos. each with 25 liters Capacity & Centrifugal pump	3 nos. each with 25 liters Capacity & Centrifugal pump
Overall Dimension:	2050mm (L) X 2000mm (W) X 1210mm (H) approx.	2450mm (L) X 2000mm (W) X 1300mm (H) approx.
Net Weight	700 kgs. approx.	900 kgs. approx.
Gross Weight	1000 kgs. approx.	1300 kgs. approx.

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.

Types of Ampoule Washing Machine

Ampoule Vial Washing Machine

Automatic Ampoule Washer

Automatic Rotary Ampoule Washing Machine

Automatic External Ampoule Washing Machine

Injectable Glass Ampoule Washing Machine

Lab Scale Ampoule Washing Machine

Multijet Ampoule Washing Machine

Rotary Ampoule Washer

Applications of Ampoule Washing Machine

Advantages of Compact Ampoule Washing Machine

Space-Saving Design for Small & Medium Facilities

Easy Integration into Production Lines

Lower Installation & Operational Costs

High Efficiency with Minimal Resource Consumption

Improved Cleanroom Compliance & Reduced Contamination Risk

Washing Cycle of Compact Ampoule Washing Machine

1^st wash	Recycled Water (WFI)
2^nd wash	Compressed Air
3^rd wash	DM Water
4^th wash	Compressed Air
5^th wash	Water for Injection (WFI)
6^th wash	Compressed Air

FAQ for Compact Ampoule Washing Machine

What is a Compact Ampoule Washing Machine?

A Compact Ampoule Washing Machine is a space-saving, high-speed, cGMP-compliant rotary washer designed for thorough internal and external cleaning of glass ampoules (1ml to 10ml / up to 20ml with change parts). Its compact footprint makes it ideal for small to medium-scale injectable manufacturing units, R&D labs, pilot plants, and facilities with limited cleanroom space. The machine uses neck-holding grippers, multiple washing stations, and independent circuits for Water for Injection (WFI), DM water, recycled water, and compressed air to ensure excellent cleaning with low breakage and minimal resource consumption.

What are the available models and production capacities of the Compact Ampoule Washing Machine?

We offer two main models:

AVRW 120: Up to 100 ampoules per minute
AVRW 240: Up to 200 ampoules per minute

Both models handle ampoules with diameters of 9mm to 21.5mm and heights of 60mm to 140mm. The compact design (approx. 2050mm L × 2000mm W × 1210mm H for AVRW 120) allows easy installation while maintaining high output and low breakage rate (≤ 0.5%).

How does the Compact Ampoule Washing Machine work?

Ampoules are loaded on the infeed tray and transferred via a feed worm to the infeed starwheel. Special grippers (15 cassettes with 2 grippers each) pick up the ampoules by the neck, invert them to a neck-down position, and move them over 6 internal washing stations (36 needles total). The machine performs 3 water washes + 3 air washes with independent circuits. External washing is done at 3 adjustable stations. After washing, ampoules are re-inverted to the upright position and discharged via the output starwheel for further processing (inline with filling/sealing or sterilization tunnel).

What materials and compliance standards does the Compact Ampoule Washing Machine follow?

All product-contact parts and wash media parts are made from AISI 316L stainless steel. Non-contact parts use AISI 304 stainless steel and engineering plastics. The machine is a complete cGMP model with smooth finishes and pharmaceutical-grade welding. It supports IQ/OQ/DQ validation documentation and optional 21 CFR Part 11 compliant PLC & HMI systems with password protection, audit trail, and printing facility.

What utilities are required to operate the Compact Ampoule Washing Machine?

The machine requires:

Power: 4 H.P. (AVRW 120) or 5.5 H.P. (AVRW 240) — 440 Volts, 3 Phase, 50 Hz (customizable as per customer requirement)
Compressed Air: 20 CFM
Water: 200 to 500 liters per hour (depending on ampoule size)

It also features optional 3 × 25-liter water tanks with centrifugal pumps and recirculation system for reduced WFI consumption. The compact size helps lower overall installation and operational costs.

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