Automatic Rotary Vial Washer

Q: What is the production capacity of the Automatic Rotary Vial Washer?

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

Q: What vial sizes can the Automatic Rotary Vial Washer handle?

The machine can efficiently wash 2ml to 100ml glass and plastic vials. It uses a gripper-based rotary system that provides gentle handling and quick changeover for different vial sizes.

Q: How many washing cycles does the Automatic Rotary 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 The machine features 6 internal washing stations (36 needles total) and 3 external washing stations.

Description

Automatic Rotary Vial Washer is a specialized pharmaceutical processing machine designed for efficiently cleaning glass or plastic vials used in injectable drug manufacturing. It operates on a rotary principle, where vials are fed into the machine, inverted, washed through multiple stations with water jets or air, and then discharged, ensuring minimal contact between the vials and machine parts to maintain sterility and comply with cGMP (Current Good Manufacturing Practice) standards. This design reduces the risk of particulate contamination and chipping, making it a reliable alternative to manual or batch-style washers.

Infeed: Unloaded vials from aturntable or tray are fed into the infeed starwheel.

Inversion and Washing: Grippers invert the vials, allowing needles to penetrate the neck for internal washing while external jets clean the body. Vials move synchronously with the needle bar for extended contact time.

Rinsing and Drying: Multiple cycles remove particulates and microbes.

Outfeed: Vials are re-inverted to upright position and ejected via outfeed starwheel to a collection tray or integrated tunnel for sterilization.

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Salient Features of Automatic Rotary Vial Washer

Complete cGMP model.
Production output capacity up to 200 vials per minute.
Digital speed indicator for current output
Non-contact parts are made from engineering plastic, AISI SS 304 materials.
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.
Suitable for 1ml to 10ml ampoules.
Automatic Infeed and Exit of containers.

All finishes, welding joints are processed, treated & equipment selected in accordance with cGMP standards.
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.
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.
All contact parts with the internal surface of Container and the wash media are made from AISI 316L Stainless Steel.
IQ/OQ/DQ documentation can be provided.
Programming and software validation as per 21 CFR Part 11 can be done on demand.

Working Principle of Automatic Rotary Vial Washer

Vials feed from the Infeed turn table / tray are received on Infeed Star wheel / Feed worm then moves on Infeed starwheel. The Grippers picks up the vial from Infeed Star Wheel and invert it in neck down position over washing needles and move along with the needle bar for Washing. Vials 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 vial 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 vials. On completion of a cycle, washed vials are again inverted to neck upward position and feed to output star wheel. Washed vials 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 Automatic Rotary 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

Double Head Ampoule Filling Machine

High Speed Vial Washing Machine

Applications of Vial Washing Machine

Key Features of Automatic Rotary Vial Washer

Capacity and Speed: Typically handles vials from 2 ml to 100 ml. Output ranges from 100 to 200 vials per minute, depending on the model.

Washing Mechanism: Vials enter neck-down via an infeed starwheel and gripper system, which holds them by the neck to invert them. They travel above washing needles that enter the vial interior for targeted cleaning. Includes 6 washing stations for sequential rinses using water for injection (WFI), purified water, or air jets. External washing nozzles ensure the vial’s outer surface is also cleaned.

Automation and Controls: Equipped with PLC for customizable wash sequences, HMI for recipe selection, and optional features like water recycling, intermittent spraying to reduce consumption, ultrasound pretreatment, or silicone treatment. Self-draining design with no moving parts in the wash zone minimizes maintenance.

Safety and Compliance: Transparent covers for visual monitoring, IQ/OQ/PQ validation support, and 21 CFR Part 11 compliant software. Changeover for different vial sizes takes under 15 minutes.

Washing Cycle of Automatic Rotary 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 Automatic Rotary Vial Washer

What is an Automatic Rotary Vial Washer?

An Automatic Rotary Vial Washer is a high-speed, fully automatic pharmaceutical machine that cleans glass and plastic vials using a rotary (circular) motion. Vials are inverted neck-down, washed internally with multiple jets/needles, and externally cleaned before being returned upright. This design ensures thorough cleaning with minimal vial-to-vial contact, making it ideal for sterile injectable production lines while meeting cGMP standards.

What is the production capacity of the Automatic Rotary Vial Washer?

We offer two standard models:

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

It is suitable for medium to high-volume injectable manufacturing.

What vial sizes can the Automatic Rotary Vial Washer handle?

The machine can efficiently wash 2ml to 100ml glass and plastic vials. It uses a gripper-based rotary system that provides gentle handling and quick changeover for different vial sizes.

How many washing cycles does the Automatic Rotary 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

The machine features 6 internal washing stations (36 needles total) and 3 external washing stations.

What are the key advantages of the Automatic Rotary Vial Washer?

Rotary design with gripper system ensures smooth, low-breakage operation
cGMP compliant with SS 316L contact parts
Independent washing circuits to prevent cross-contamination
Low water & air consumption with recycling options
PLC + HMI control with optional 21 CFR Part 11 compliance
Suitable for both standalone and inline operation with depyrogenation tunnel
Compact footprint with easy maintenance

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