Aseptic Glass Vial Washing Machine

Q: What production capacities and vial sizes does the machine support?

The machine is available in two main models: AVRW 120 : Up to 100 vials per minute. AVRW 240 : Up to 200 vials per minute. It handles 2 ml to 100 ml glass and plastic vials. A special pocket system allows flexible handling with no change parts required, enabling quick and easy format changes with minimal downtime.

Q: How many washing cycles does the Aseptic Vial Washing Machine perform?

It performs 6 standard washing cycles with independent circuits to prevent cross-contamination: Recycled Water (WFI) Compressed Air DM / Purified Water Compressed Air Fresh Water for Injection (WFI) Compressed Air Cycles are customizable according to customer requirements. Vials are washed internally and externally using multi-jet sprayers and indexing motion for thorough cleaning.

Q: What are the key features and construction materials of the machine?

All product contact parts are made from high-quality AISI SS 316L stainless steel. Tanks, trays, nozzles, and pumps use SS 316L with argon-welded round corners. Robust structure (SS 304), PLC with HMI and printing facility, variable frequency drives, and a special clutch for safety. Features include HDPE vial pockets, wire-woven infeed belt, tool-free operation, low maintenance, and energy-efficient design with minimal water usage.

Q: What industries use this machine and what are its main benefits?

It is primarily used in the Pharmaceutical, Biotech, Cosmetic, and Chemical industries for sterile production. Key benefits include: Superior contamination control and near-zero particle counts. High efficiency, cost savings, and regulatory compliance (cGMP, FDA, EMA). Gentle handling (no glass-to-glass contact), easy integration with sterilizing tunnels and filling lines, and optional features like safety cabinets or siliconization.

Description

Aseptic Glass Vial Washing Machine are specialized equipment used in the pharmaceutical and biotechnology industries to clean glass vials under sterile (aseptic) conditions. These machines ensure the removal of contaminants, particles, and residues from the interior and/or exterior surfaces of vials, preparing them for subsequent processes like sterilization, depyrogenation, filling, and sealing. They are critical for maintaining compliance with Good Manufacturing Practices (cGMP) and preventing microbial contamination in the production of injectables, vaccines, and other sterile products. Typically handling vials from 2R (2 ml) up to 500 ml, these machines operate in controlled environments such as cleanrooms, Restricted Access Barrier Systems (RABS), or isolators to uphold aseptic standards.

Contamination Control: Achieves near-zero particle counts, reducing cross-contamination risks in toxic or high-potency drug production.

Efficiency and Cost Savings: Tool-free format changes, low maintenance, and high yields lower operational costs. For instance, CFD-optimized flows ensure thorough cleaning with minimal water.

Regulatory Assurance: Designed for OEB5/BSL2 levels, with 100% in-process controls (IPC) for quality.

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Salient Features of Aseptic Glass Vial Washing Machine

Provides production output up to 120 vials per minute.
All contact parts made from high quality stainless steel AISI SS 316L.
SS Tanks & trays made from SS 316L by argon welded with round corner.
SS filter housing made from SS 316L.
Special Pocket system ensures easy and trouble free washing of vials from outer and inner side.
User friendly machine, even semi skilled operator can operate the machine very easily.
Pumps with tank (60 litres each) 2 nos.
A Special clutch device is incorporated for Stoppage of Machine in the event; vial is over turned or over diameter.
Machine is totally robust and withstands continues operation for long working hours without any trouble.
No Change parts are required.

Machine structure & other parts made from AISI SS 304.
SS pump made from SS 316L with mechanical seal Monoblock pump.
All Nozzles made from SS 316L.
In feed Wire Woven Belt for feeding of Vials.
Indexing motion makes easier for syringes to move inside vial, when it is in stationery motion.
Washing cycles can be adjusted as per customer requirement.
Variable A.C. Frequency drive for Main drive and conveyor.
HDPE material Vial pockets.
Machine is equipped with PLC system & printing facility with passwords.
Third Tank & pump can be fitted (optional).

Working Principle of Aseptic Glass Vial Washing Machine

Vials pushed from in feed tray and then move on wire woven conveyor belt, which align the vial in correct position, to enter in to the carrier pocket with help of oscillating guide rails. Oscillating arm deliver the vial inside pocket in mouth down position over spraying nozzles. Multijet sprayers fixed at the top cause the total external and internal surface to be washed. To avoid any possible cross contamination between two different waters, each washing station is provided with an independent circuit. Carrier pocket is moving with indexing motion. When the baskets have completed their motion the needles are lifted. They penetrate the vials, spraying jets of water or compressed air then return down. The baskets movement then advances by one station. Each station of vials passes through the washing cycles selected. The duly washed vials then delivered to the out feed tray with neck opening upward and then automatically re ordered to sterilizing tunnel with back pressure.

The process typically involves automated feeding, multi-stage washing, rinsing, and drying, all under aseptic conditions:

Infeed and Orientation: Empty glass vials are loaded via a buffer system, turntable, or conveyor. Vials are often inverted or rotated for optimal access to surfaces.

Washing/Rinsing: High- or low-pressure water jets (or air-assisted sprays) target interior and exterior surfaces. For external washers, vials rotate while nozzles clean from neck to bottom, removing product residues or particles. Internal washing uses inverted spraying with clean water, often in multiple cycles (e.g., pre-wash, detergent wash, final rinse) to achieve high efficiency.

Drying: Hot sterile air or compressed facility air is blown through the vials to evaporate moisture, ensuring no residue remains. Some models use on-board blowers for consistent results.

Outfeed and Inspection: Clean, dry vials are transferred to downstream equipment like sterilizers or fillers. Inline checks for defects may use high-resolution cameras.

Technical Specification of Aseptic Glass Vial Washing Machine

Model	AVRW 120	AVRW 240
Production Output	Up to 100 per minute	Up to 200 per minute
Vial Sizes	2ml to 100ml	2ml to 100ml
Type of Vials	Glass & Plastic Vials	Glass & Plastic Vials
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 Vial Washing Machine

Automatic Vial Washing Machine

Rotary Vial Washing Machine

Multijet Vial Washing Machine

Linear Vial Washing Machine

Automatic External Vial Washing Machine

High Speed Vial Washing Machine

Applications of Vial Washing Machine

Key Features of Aseptic Glass Vial Washing Machine

Material and Construction: Constructed from high-grade stainless steel with polished surfaces for easy cleaning and corrosion resistance. Tempered glass windows and doors allow visual monitoring, and designs often include easy-access service panels for minimal downtime.

Capacity and Speed: Throughputs range from 100 to 6,000 vials per minute (vpm), suitable for small-batch R&D/clinical trials to high-volume production.

Water and Energy Efficiency: Advanced designs reduce water consumption by up to 45% through optimized nozzles and recirculation systems. Ultrasonic pre-treatment options enhance cleaning without excessive resource use.

Integration: Often integrated into full aseptic lines, including depyrogenating tunnels for dry heat sterilization post-washing.

Safety and Compliance: Equipped with HEPA-filtered enclosures, negative pressure options, and compatibility with Vaporized Hydrogen Peroxide (VHP) for decontamination. Menu-driven Human-Machine Interfaces (HMIs) ensure operator safety and traceability.

Washing Cycle of Aseptic Glass Vial 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 Aseptic Glass Vial Washing Machine

What is an Aseptic Glass Vial Washing Machine and why is it important?

An Aseptic Glass Vial Washing Machine is specialized pharmaceutical equipment designed to clean glass (and plastic) vials under sterile conditions. It removes contaminants, particles, pyrogens, and residues from both internal and external surfaces before sterilization, depyrogenation, filling, and sealing. It is critical for maintaining cGMP compliance, preventing microbial contamination, and ensuring the safety of injectable drugs, vaccines, and other sterile products in cleanroom, RABS, or isolator environments.

What production capacities and vial sizes does the machine support?

The machine is available in two main models:

AVRW 120: Up to 100 vials per minute.
AVRW 240: Up to 200 vials per minute.

It handles 2 ml to 100 ml glass and plastic vials. A special pocket system allows flexible handling with no change parts required, enabling quick and easy format changes with minimal downtime.

How many washing cycles does the Aseptic Vial Washing Machine perform?

It performs 6 standard washing cycles with independent circuits to prevent cross-contamination:

Recycled Water (WFI)
Compressed Air
DM / Purified Water
Compressed Air
Fresh Water for Injection (WFI)
Compressed Air

Cycles are customizable according to customer requirements. Vials are washed internally and externally using multi-jet sprayers and indexing motion for thorough cleaning.

What are the key features and construction materials of the machine?

All product contact parts are made from high-quality AISI SS 316L stainless steel.
Tanks, trays, nozzles, and pumps use SS 316L with argon-welded round corners.
Robust structure (SS 304), PLC with HMI and printing facility, variable frequency drives, and a special clutch for safety.
Features include HDPE vial pockets, wire-woven infeed belt, tool-free operation, low maintenance, and energy-efficient design with minimal water usage.

What industries use this machine and what are its main benefits?

It is primarily used in the Pharmaceutical, Biotech, Cosmetic, and Chemical industries for sterile production. Key benefits include:

Superior contamination control and near-zero particle counts.
High efficiency, cost savings, and regulatory compliance (cGMP, FDA, EMA).
Gentle handling (no glass-to-glass contact), easy integration with sterilizing tunnels and filling lines, and optional features like safety cabinets or siliconization.

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Aseptic Glass Vial Washing Machine

Description

Salient Features of Aseptic Glass Vial Washing Machine

Working Principle of Aseptic Glass Vial Washing Machine

Technical Specification of Aseptic Glass Vial Washing Machine

Types of Vial Washing Machine

Applications of Vial Washing Machine

Key Features of Aseptic Glass Vial Washing Machine

Washing Cycle of Aseptic Glass Vial Washing Machine

FAQ for Aseptic Glass Vial Washing Machine

Countries We Export to

Partner with Industry Experts

Countries We Export to

Partner with Industry Experts

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