Linear Vial Washer

A Linear Vial Washer is an automated industrial machine designed for the thorough cleaning and decontamination of pharmaceutical glass vials (and sometimes plastic or oval containers) used in injectable drug production. It operates on a linear conveyor system, where vials are transported through a series of washing stations in a straight-line path, ensuring efficient, high-volume processing while adhering to cGMP (Current Good Manufacturing Practice) standards. This contrasts with rotary washers, which use a carousel mechanism. The machine is essential in pharmaceutical, biotechnology, and sterile product manufacturing to remove contaminants, particles, and pyrogens from vial interiors and exteriors before filling.

Linear Vial Washer Video

Key Components and Operation

• In-Feed and Transport: Vials are loaded mouth-down onto an in-feed turntable or conveyor belt, aligned by oscillating guide rails, and fed into carrier pockets or baskets. They move linearly through the machine via a wire-woven conveyor or indexing motion.

• Washing Stations: Typically features 4-5 water wash zones and 2-3 air rinse zones. High-pressure spray nozzles penetrate the vial’s neck and interior, spraying jets of cleaning solutions or compressed air to ensure complete coverage without dripping contaminated water back onto the vials.

• Out-Feed: Cleaned vials are positively discharged onto an out-feed conveyor, ready for subsequent filling or sterilization.

• Pumping and Filtration: Includes independent pumps, tanks, filter housings, and cartridge filters for each washing circuit to prevent cross-contamination. Many models incorporate a recycled water loop to minimize WFI consumption while maintaining high cleaning efficacy.

Main Features and Benefits

• Efficiency and Output: Processes 2-30 ml round glass vials at speeds up to 200-240 vials per minute, with low water usage and quick changeovers.

• Safety and Durability: Constructed from SS 316L (contact parts) and SS 304 (non-contact), with acrylic safety doors, vibration-free design, and overload protection to prevent vial breakage. Segregated process, mechanical, and circuit areas avoid contamination.

• Customization: Flexible washing cycles, microprocessor-based AC frequency drives for speed control, vial counters, and options for pyrogen reduction or high-pressure washing without container movement.

• Space Optimization: Compact linear footprint suits inline sterile production lines, reducing labor and human error through full automation.

Salient Features of Linear Vial Washing Machine

• Compact cGMP model.

• Provides production output up to 250 vials per minute.

• All contact parts made from high quality stainless steel AISI SS 316L.

• Machine structure & other parts made from AISI SS 304

• SS Tanks & trays made from SS 316L by argon welded with round corner.

• SS pump made from SS 316L with mechanical seal Monoblock pump.

• SS filter housing made from SS 316L.

• All Nozzles made from SS 316L.

• Special Pocket system ensures easy and trouble free washing of vials from outer and inner side.

• Indexing motion makes easier for syringes to move inside vial, when it is in stationery motion.

• No Change parts are required from 5 ml to 30 ml vial.

• Washing cycles can be adjusted as per customer requirement.

• User friendly machine, even semi skilled operator can operate the machine very easily.

• A Special clutch device is incorporated for Stoppage of Machine in the event; vial is over turned or over diameter.

• Variable A.C. Frequency drive for Main drive and conveyor.

• Pumps with tank (60 litres each) 2 nos.

• In feed Wire Woven Belt for feeding of Vials.

• HDPE material Vial pockets.

• Machine is totally robust and withstands continues operation for long working hours without any trouble.

• Machine is equipped with PLC system & printing facility with passwords.

• No Change parts are required.

Process Operation of Linear Vial Washer 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 Linear Vial Washer

* 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.

Send Inquiry