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The vial powder washing-drying-filling-stoppering-capping-labeling production line is made up of vertical ultrasonic bottle washing machine, hot air circulating sterilizing tunnel oven and numerically controlled screw filling machine, capping machine and labeling machine, and each unit can also be used separately.
The vial powder production line is suitable for the production of 7-25ml vial powder injections. It can complete twenty or so processes, including spraying water, ultrasonic rough washing, water flushing of bottle outer wall, two times recycled water flushing of bottle inner wall, air blowing, clean water flushing, two times clean air blowing, blowing of bottle outer wall, preheating, drying, sterilizing and pyrogen removing, cooling, powder filling, stoppering, capping, labeling and so on.
Vial bottle washing machine
1. The bottle washing machine adopts a mechanical arm to grip bottle and therefore is suitable for vials with various specifications;
2. The ultrasonic bottle washing machine has good cleaning effect and saves energy by reciprocated tracking and inserting spraying needle into the bottle for water and air washing, and it is equipped with an anti-vibration rack, so as to improve the accuracy of inserting the spraying needle into the bottle and reduce the occurrence of needle breaking;
3. The bottle washing machine separates its water spraying process from all water pipelines, thus avoiding cross contamination and complying with the GMP requirements;
4. The bottle washing machine feeding screw has a buffer block to protect it and reduce bottle breaking risks;
5. The whole bottle washing machine applies the imported synchronous belt to connect to the block used for transferring the cleaned vials, with stable and reliable operation;
Vial bottle drying and sterilizing tunnel oven
1. Heated by hot circulating air, the hot air circulating sterilizing tunnel oven is energy-efficient with uniform temperature inside;
2. The hot air circulating sterilizing tunnel oven is of protection function against sudden power failure, thus keeping safe operation;
3. The hot air circulating sterilizing tunnel oven is equipped with circulating water cooling device, which doesn’t consume air volume in the room, reduces the risk of pressure difference imbalance and has satisfactory cooling effect;
4. The hot air circulating sterilizing tunnel oven is configured with automatic pressure difference balance adjustment system to minimize high temperature discrepancy, temperature rise in the filling room and washing and drying room, etc., caused by pressure difference imbalance between the room and the oven.
5. The hot air circulating sterilizing tunnel oven is set with DOP test port, including air pressure, air speed and dust particles test ports;
6. The hot air circulating sterilizing tunnel oven is configured with sterilization function at the cooling section (FDA requires);
7. The hot air circulating sterilizing tunnel oven mesh belt can be equipped with ultrasonic and CIP systems;
Vial filling stoppering capping machine
1. The filling machine adopts advanced design idea, with high-speed and accurate operation and being convenient for changes parts replacement;
2. The filling machine adopts AC servo motor to drive the filling screw to rotate, thus ensuring precise powder filling;
3. The filling machine achieves adjustment of filling volume directly through the touch screen;
4. The filling machine can be configured with class 100 circulating laminar flow unit;
5. The filling machine has no bottle no filling, and no bottle no stoppering functions;
6. PLC (programmable logic controller) master control, frequency converter and touch screen control technology are adopted with stable and reliable operation; the touch screen can display the running status of each single machine, water pressure, air pressure, wind pressure, temperature, etc. of each control point, the on-off state of each switch and fault, self-diagnosis and fault analysis and troubleshooting methods, enabling the entire production process to achieve automatic control. The automatic balancing device is used in the production line to guarantee balanced and reliable production.
The following configurations can be adopted according to the customers’ requirements:
1. Control systems of such brands as Siemens, Schneider, Mitsubishi and Delta;
2. On-line detection of water and air pressure, water temperature and ultrasonic intensity, dust particles and wind speed, alarm and record function and printing system;
3. ORABS, CRABS and sterile isolator system.
