Tunnel Type Vial Washing Machine

A Tunnel Type Vial Washing Machine (also known as an Automatic Linear Tunnel Type Vial Washing Machine) is a specialized, automated piece of equipment primarily used in the pharmaceutical, biotechnology, and injectable drug manufacturing industries. It is designed to thoroughly clean both the internal and external surfaces of glass vials (typically round vials ranging from 2 ml to 100 ml in size) to ensure they are free from contaminants, particles, and residues before filling with sterile products like vaccines, injectables, or medications. This machine operates on a linear conveyor system within a enclosed “tunnel” structure, which maintains separation between the loading (dirty) and unloading (clean) zones to prevent cross-contamination, adhering to cGMP (Current Good Manufacturing Practice) standards.

Tunnel Type Vial Washing Machine Video

Key Design and Operational Features

• Tunnel Configuration: Vials are loaded onto a stainless steel (SS) wire mesh conveyor or fed manually via a feed table. They move intermittently through a series of enclosed washing stations inside the tunnel, where high-pressure jets of cleaning agents are applied. The tunnel design ensures a controlled environment, with easy integration to downstream equipment like sterilizing tunnels.

• Washing Process:

  • Internal Washing: Typically features 8–10 stations using penetrating nozzles that insert into the vial neck for precise cleaning. Common sequences include compressed air (for initial blowing), recirculated water, deionized (DM) water, and fresh Water for Injection (WFI). This ensures deep cleaning without residue.

  • External Washing: 2 stations for surface rinsing, often with recirculated water followed by WFI jets.

  • Customization: Washing sequences can be modified based on requirements. High-pressure spray nozzles guarantee uniform coverage, and a “no container, no water” system saves resources.

• Automation and Controls: Fully automated with PLC and touchscreen HMI (Human-Machine Interface) for interlocks, alarms, and sequence control. Magnetic valves electrically time spray durations. Emergency stops and low-maintenance pumps enhance safety.

• Material Construction: Entire frame and contact parts are made from AISI 304/316 stainless steel for corrosion resistance and hygiene. Pipes, tanks, and pumps are also SS 316. No change parts needed for vials 5–30 ml; minimal adjustments for neck size variations.

• Loading/Unloading: Automatic loading via conveyor; unloading directly to trays or a turntable. Vibration-free operation for smooth, noiseless performance.

Applications and Benefits

• Primary Use: Essential for vial preparation in aseptic filling lines, ensuring sterility and compliance with FDA/USP standards.

• Advantages:

  • High efficiency and throughput with minimal manual intervention, reducing human error and contamination risks.

  • Water recycling options for sustainability.

  • Versatile for various vial formats with quick changeovers.

  • Robust for continuous operation in cleanrooms.

Salient Features of  Vial Washer Machine

• A complete cGMP model.

• All contact parts made from S.S. 316L.

• Entire frame covers & non contact parts made out from SS 304.

• Easy cleanable & Inter changing facility.

• Machine provides 4 water washers & 3 air washers.

• Complete Flexibility with user for washing cycle.

• Feeding online vial transferring chain through turn table.

• “No Vial – No Washing” system.

• “No washing – No water supply” system.

• Nozzles enter into the container during washing cycle to meet cGMP requirement.

• Low water consumption.

• Quick change over with minimum use of tools.

• Microprocessor based variable AC frequency drive for speed control.

• Vial counter for counting the final production output.

Process Operation of Tunnel Type Vial Washing Machine

Containers feed from the de-cartooning station are received on an Infeed turn table through visual inspection unit. An in feed worm inverts container to neck down position and feeds them through a specially designed indexing device. The device carries the container forward and stops. Nozzles carrier enters into the container and activities the jet of water/air. The air/water flow is deactivated after the washing cycle is over. Device indexes the vials for next wash. A separate pumping station gives the right quantum of water at the desired pressure. Washed containers are again inverted to neck upward position to collect in trays or directly feed to sterilizing tunnel.

Technical Specification of Vial Washing Machine

* 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.