A Rotary Vial Washing Machine is a high-speed, fully automatic pharmaceutical equipment designed for external and internal cleaning of glass vials (typically 2 ml to 100 ml) used in injectable formulations. It ensures thorough removal of particulate matter, pyrogens, and contaminants through a continuous rotary motion, making it ideal for sterile pharmaceutical production lines.
Rotary Vial Washing Machine Video
Key Features
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Continuous Rotary Operation: Vials are indexed through multiple washing stations in a circular path, ensuring high output.
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Needle-Based Cleaning: Diving needles enter each vial for precise internal jet washing; external washing via fixed or rotary sprays.
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No Vial – No Wash System: Sensors detect absence of vials and stop water/air jets to save utilities.
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GMP Compliance: Complete SS 304/316 construction, mirror-polished contact parts, acrylic or toughened glass enclosure, and easy-clean design.
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PLC + HMI Controlled: Fully automated with recipe management, fault alarms, and data logging.
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Aseptic Design: Suitable for cleanroom installation.
Applications
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Pharmaceutical injectables (ampoules & vials)
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Biotech and vaccine production
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Ideal linkage with depyrogenation tunnels (DHS) and automatic vial filling lines
Salient Features of Rotary Vial Washer Machine
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Complete cGMP model.
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Production output capacity up to 200 vials per minute.
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All contact parts with the internal surface of Container and the wash media are made from AISI 316L Stainless Steel.
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Non-contact parts are made from engineering plastic, AISI SS 304 materials.
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All finishes, welding joints are processed, treated & equipment selected in accordance with cGMP standards.
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Machine provides 3 water washes & 3 Air washes.
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Complete flexibility with user for washing cycle.
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18 Jets for 6 internal washing zones.
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15 Cassette of Grippers each having 2 Grippers.
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Suitable for 1ml to 10ml ampoules.
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Washing sequence can be adjusted as per customer’s requirements.
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3 Pumps and 3 Tanks of 25 liters each. (Optional)
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Each washing zone with independent circuit to avoid contamination.
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Automatic Infeed and Exit of containers.
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Machine is equipped with PLC system & printing facility with passwords. (Optional)
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Container unit counter with display in the control panel
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Machine can use as a sole machine or inline.
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Digital speed indicator for current output
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IQ/OQ/DQ documentation can be provided.
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Programming and software validation as per 21 CFR Part 11 can be done on demand.
Working Principle of 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.
Washing Cycle of Vial Washing Machine
- 1st wash – Recycled Water (WFI)
- 2nd wash – Compressed Air
- 3rd wash – DM Water
- 4th wash – Compressed Air
- 5th wash – Water for Injection (WFI)
- 6th wash – Compressed Air
Technical Specification of Rotary Vial Washing Machine
| Models | AI-DPM 12 | AI-DPM 16 |
| Production Output | Up to 80 bottles/minute | Up to 120 bottles/minute |
| Bottle Diameter | Up to 85mm | Up to 85mm |
| Bottle Height | Up to 200mm | Up to 200mm |
| Fill Volume | 5gms. To 70gms. in Single Dose with the help of change parts for different fill volume | 5gms. To 70gms. in Single Dose with the help of change parts for different fill volume |
| Fill Accuracy | ± 2% Depending upon the Powder, under the controlled level of Humidity | ± 2% Depending upon the Powder, under the controlled level of Humidity |
| Humidity | Below 28% Rh required on machine to be arrange by customer | Below 28% Rh required on machine to be arrange by customer |
| Power | 2.0 H.P. For Machine and 3.0 H.P. For Vacuum Pump | 2.5 H.P. For Machine and 3.0 H.P. For Vacuum Pump |
| Overall Dimension | 1700 mm (L) x 1000 mm (W) x 1800 mm approx. | 2000 mm (L) x 1200 mm (W) x 1800 mm 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.
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