Vial Washing Machine

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

The machine can handle a wide range of vial sizes from 2ml to 100ml . It supports both glass and plastic vials. The system uses a special pocket design that allows easy and trouble-free washing without requiring change parts for different sizes in the standard model.

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

We offer two main models: AVRW 120 : Up to 100–120 vials per minute AVRW 240 : Up to 200 vials per minute The output depends on the model and vial size.

Q: What are the key features of this Vial Washing Machine?

Key features include: All contact parts made of SS 316L Automated PLC + HMI control system Multiple washing stations with independent circuits Special clutch mechanism to prevent damage from overturned vials Infeed wire woven belt and indexing motion for precise washing Low water and air consumption with recycling options Easy to operate and maintain

Description

Vial Washing Machine is specialized pharmaceutical equipment designed to clean and decontaminate glass or plastic vials used for injectable drugs, vaccines, or sterile products. It ensures vials are free from particles, residues, and contaminants before filling and sealing, complying with strict cGMP (Current Good Manufacturing Practice) standards. These machines are essential in aseptic processing lines to prevent cross-contamination and maintain sterility, often integrated with filling, capping, and sterilizing systems. Constructed entirely from AISI 304/316 stainless steel, the machine offers excellent corrosion resistance, durability, and easy cleaning. The automated PLC/HMI control system enables precise process control, user-friendly operation, and consistent washing performance. The machine is widely used in pharmaceutical, biotechnology, veterinary, and injectable manufacturing facilities.

The machine typically consists of an unscrambling table, infeed system, washing chamber, and outfeed conveyor. Vials are automatically fed into the machine, indexed through multiple washing stations, and cleaned using a sequence of purified water, WFI (Water for Injection), and sterile compressed air. Advanced nozzle systems provide thorough internal and external washing to achieve high cleanliness standards. It is typically the first machine in a sterile vial filling line.

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Salient Features of 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 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 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

Advantages of Vial Washing Machine

High Cleaning Efficiency

Ensures Sterility & Product Safety

High Production Speed & Efficiency

Consistency & Reproducibility

Improved Compliance & Validation

Key Features of Vial Washing Machine

Vial Washing Machines typically operate through automated processes involving high-pressure jets, air rinses, and vacuum systems. They handle vial sizes from 1ml to 500ml and achieve speeds up to 30,000 vials per hour, depending on the model. Common features include:

Non-Contact Washing: Nozzles penetrate vials without touching interiors, using air-vacuum pre-cleaning to remove loose particles.

Flexible Wash Sequences: Programmable cycles with multiple stations (e.g., 6 stations) for water, air, or WFI (Water for Injection) rinses, minimizing WFI consumption via recycled loops.

Segregated Zones: Separate areas for mechanical drives, washing, and filtration to avoid contamination.

Safety Mechanisms: “No Vial – No Wash” sensors, overload protection to prevent breakages, and acrylic enclosures for visibility.

Drying Options: Post-wash air jets or tunnels for complete drying.

FAQ for Vial Washing Machine

What is a Vial Washing Machine?

A Vial Washing Machine is specialized pharmaceutical equipment designed to clean glass and plastic vials both internally and externally. It removes dust, particles, residues, and contaminants using multiple washing cycles with Purified Water (PW), Water for Injection (WFI), and sterile compressed air. It is typically the first machine in a sterile vial filling line and ensures compliance with cGMP standards.

What vial sizes can the Vial Washing Machine handle?

The machine can handle a wide range of vial sizes from 2ml to 100ml. It supports both glass and plastic vials. The system uses a special pocket design that allows easy and trouble-free washing without requiring change parts for different sizes in the standard model.

What is the production capacity of the Vial Washing Machine?

We offer two main models:

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

The output depends on the model and vial size.

What are the key features of this Vial Washing Machine?

Key features include:

All contact parts made of SS 316L
Automated PLC + HMI control system
Multiple washing stations with independent circuits
Special clutch mechanism to prevent damage from overturned vials
Infeed wire woven belt and indexing motion for precise washing
Low water and air consumption with recycling options
Easy to operate and maintain

Why is a Vial Washing Machine important in injectable production?

Vial washing is a critical step in sterile manufacturing. It ensures vials are free from particulate matter and microbial contamination before sterilization and filling. This helps maintain product sterility, reduces rejection rates, ensures regulatory compliance (cGMP, FDA, EU-GMP), and protects patient safety for injectable drugs and vaccines.

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