Aseptic Vial Washer

Q: What is the production capacity of the Aseptic Vial Washer?

We offer two standard models: AVRW 120 : Up to 100 vials per minute AVRW 240 : Up to 200 vials per minute These models are suitable for medium to high-volume sterile injectable manufacturing lines.

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

It performs 6 washing cycles as standard: Recycled Water (WFI) Compressed Air DM Water / Purified Water Compressed Air Fresh Water for Injection (WFI) Compressed Air Each station has an independent circuit to prevent cross-contamination. Cycles can be customized as per customer requirements.

Description

Aseptic Vial Washer (also known as a Sterile Vial Washing Machine or Aseptic Vial Cleaning System) is a specialized, high-purity pharmaceutical processing equipment designed to thoroughly clean and prepare glass or plastic vials for aseptic filling operations in compliance with cGMP, FDA, EMA, and Annex 1 requirements.

External and internal washing of vials using purified water (PW), Water for Injection (WFI), and clean compressed air or nitrogen
Removal of particulate matter, pyrogens, and microbial contamination
Siliconization (optional) for vials requiring lubrication
Sterilization preparation (typically followed by depyrogenation tunnel)

If you need details on specific models and pricing. let me know!

Salient Features of Aseptic Vial Washer

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 Vial Washer

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.

Technical Specification of Aseptic Vial Washer

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 Vial Washer

Fully automatic, continuous or intermittent motion operation

No glass-to-glass contact (vial transport via grippers or walking beam)

Validatable cleaning efficiency (>3–6 log reduction in particles/endotoxins)

21 CFR Part 11 compliant controls, full recipe management, and audit trail

RABs or isolator integration for Grade A containment

Low water and energy consumption designs (water recirculation systems)

Washing Cycle of Aseptic Vial Washer

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 Vial Washer

What is an Aseptic Vial Washer?

An Aseptic Vial Washer is a high-performance, fully automatic vial cleaning machine designed for sterile and aseptic pharmaceutical production. It thoroughly cleans the internal and external surfaces of glass and plastic vials using purified water (PW), Water for Injection (WFI), and compressed air/nitrogen to remove particles, pyrogens, and microbial contamination — preparing vials for aseptic filling in compliance with cGMP, FDA, EMA, and EU Annex 1 guidelines.

What is the production capacity of the Aseptic Vial Washer?

We offer two standard models:

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

These models are suitable for medium to high-volume sterile injectable manufacturing lines.

What vial sizes can the Aseptic Vial Washer handle?

The machine can process 2ml to 100ml glass and plastic vials. It uses a special pocket system and requires no change parts for different vial sizes, enabling fast and easy changeover with minimal downtime.

How many washing cycles does the Aseptic Vial Washer perform?

It performs 6 washing cycles as standard:

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

Each station has an independent circuit to prevent cross-contamination. Cycles can be customized as per customer requirements.

What are the key advantages of the Aseptic Vial Washer?

Designed specifically for aseptic and sterile production environments
cGMP compliant with SS 316L contact parts and high cleaning efficiency
No glass-to-glass contact for gentle vial handling
PLC + HMI control with recipe management and audit trail (21 CFR Part 11 compliant)
Low water and air consumption with “No Vial – No Washing” system
Easy integration with depyrogenation tunnel and filling lines
Optional siliconization and isolator/RABS compatibility

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