Injectable Glass Vial Washing Machine

Q: What is the production capacity of the Injectable Glass Vial Washing Machine?

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

Q: What vial sizes can the Injectable Glass Vial Washing Machine handle?

The machine can efficiently wash 2ml to 100ml glass and plastic vials. It features a special pocket system and requires no change parts for different vial sizes, allowing quick and easy changeover.

Q: What washing cycles does the Injectable Glass Vial Washing Machine 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 Both internal and external surfaces are thoroughly cleaned using multijet spraying nozzles.

Description

Injectable Glass Vial Washing Machine is a specialized piece of pharmaceutical equipment designed to clean glass vials used for injectable drugs, ensuring sterility and compliance with standards like cGMP (Current Good Manufacturing Practice) and FDA regulations. These machines are essential in the production of parenteral (injectable) medications, where even microscopic contaminants can pose serious health risks. They typically handle vials ranging from 2ml to 100ml in size and are integrated into larger filling lines that include sterilization, filling, sealing, and labeling processes. These washers remove particulates, residues, and pyrogens from both the interior and exterior of vials using high-pressure jets of purified water (e.g., Water for Injection or WFI), air, or filtered solutions. Common configurations include multi-jet systems for thorough internal cleaning and linear or rotary setups for high-volume production.

Loading: Vials are fed via turntable or conveyor (manual tray for semi-automatic models).

Inversion: Grippers hold vials by the neck and invert them to expose the interior.

Washing Cycle: Nozzles inject jets of filtered water/air. Sequences often include:
- Pre-rinse with purified water.
- Internal/external jets (5–10 microns filtration).
- Air blow-dry to remove moisture.
- Optional ultrasonic or hot air for enhanced cleaning.

Drying/Sterilization: Vials pass through a tunnel with HEPA-filtered hot air (300–320°C) for 5+ minutes to sterilize and depyrogenate.

Unloading: Reoriented vials exit to filling stations.

This process ensures vials meet USP <797> standards for sterile injectables, with validation protocols for particle counts and endotoxin levels.

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

Salient Features of Injectable 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 Injectable 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.

Technical Specification of Injectable 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 Injectable Glass Vial Washing Machine

cGMP & Regulatory Compliance — Designed and constructed per current Good Manufacturing Practices (cGMP), FDA, and international standards. Contact parts are typically made of AISI SS 316L, with non-contact parts in SS 304 or engineering plastics. All finishes and welds meet pharmaceutical requirements.

Multi-Stage Washing Cycles — Supports customizable and programmable washing sequences, often including:
- Internal washes (typically 6–8 stages): Compressed air, recirculated water, purified/DM water, and fresh WFI (Water for Injection).
- External washes (usually 2 stages).
- Final air blowing/drying for moisture removal.

High Cleaning Efficiency — Uses high-pressure spray nozzles and inverted vial handling (in many models) for thorough internal flushing. Ensures removal of particulates and achieves low bioburden levels.

Versatility in Vial Sizes — Handles a wide range (commonly 2ml to 100ml or up to 125ml) with minimal or no change parts for round vials. Quick changeover capability supports multi-product facilities.

Automation & Controls — PLC-based system with touchscreen HMI for easy operation, recipe management, and monitoring of critical parameters (pressure, temperature, cycle time). Features like “No Vial – No Washing” to save resources.

Linear or Rotary Configurations:
- Linear (Tunnel Type): Conveyor-based for flexibility, compact footprint, and easier maintenance.
- Rotary: Gripper-based for higher speeds and precise handling.

Safety & Protection Features — Safety interlocks (machine stops if guards open), clutch systems to prevent vial damage/jams, and enclosed design to minimize recontamination. HEPA-filtered air options in some models.

Compact & Efficient Design — Space-saving footprint with high output (60–400+ vials per minute depending on model). Includes water recycling systems to reduce WFI consumption and operational costs.

Easy Maintenance & Validation — Modular design for easy cleaning, accessibility, and qualification (IQ/OQ/PQ). Low maintenance due to robust construction.

Integration Ready — Seamlessly connects with depyrogenation tunnels, filling, and capping machines in a complete sterile line.

These features make the machine essential for ensuring sterility assurance, particulate control, and regulatory compliance in injectable manufacturing (e.g., vaccines, antibiotics, biologics).

Note: Features can vary between linear vs. rotary and manufacturer-specific models. Linear types are often preferred for flexibility, while rotary suits very high-speed needs.

Washing Cycle of Injectable 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 Injectable Glass Vial Washing Machine

What is an Injectable Glass Vial Washing Machine?

An Injectable Glass Vial Washing Machine is a fully automatic, high-speed washing system designed to clean glass (and plastic) vials used for injectable drugs. It performs both internal and external washing using high-pressure jets to remove particles, residues, and pyrogens, ensuring the vials meet cGMP and FDA standards before sterilization and filling.

What is the production capacity of the Injectable Glass Vial Washing Machine?

We offer two standard models:

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

These models are ideal for medium to high-volume injectable production lines.

What vial sizes can the Injectable Glass Vial Washing Machine handle?

The machine can efficiently wash 2ml to 100ml glass and plastic vials. It features a special pocket system and requires no change parts for different vial sizes, allowing quick and easy changeover.

What washing cycles does the Injectable Glass Vial Washing Machine 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

Both internal and external surfaces are thoroughly cleaned using multijet spraying nozzles.

What are the key advantages of the Injectable Glass Vial Washing Machine?

Fully automatic linear operation with high output
cGMP compliant with SS 316L contact parts
No change parts required for different vial sizes
PLC + HMI control with recipe management (optional)
Low water & air consumption with “No Vial – No Washing” system
Easy integration with Sterilizing Tunnel and Filling Line
Robust construction for continuous long-hour operation

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Connect with our engineering team to discuss your specific production requirements. We provide customized, cGMP-compliant machinery solutions designed to optimize your manufacturing facility and maximize output.

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