The vial liquid washing-drying-filling-stoppling production line is composed of the vertical ultrasonic bottle washing machine, tunnel hot air circulation sterilizing oven and vial liquid filling-stoppering machine, whilst the three component machines can also be used independently. Suitable for production of vial injection of 2-25ml, it can complete more than 20 procedures such as spray and water filling, ultrasonic rough washing, bottle exterior wall washing, bottle interior wall continuous twice circulation water washing, primary blowing, primary fresh water washing, continuous twice blowing, bottle exterior wall blowing, preheating, drying, sterilizing, pyrogen removing, cooling, front gas charging, filling, rear gas charging, stoppering, and etc.
The whole line adopts PLC main control, frequency converter and touch screen control technology with stable and reliable running. The touch screen can display running dynamics of each single machine, water pressure, air pressure, wind pressure and temperature at each control point. The display of each on-off status and faults, fault self-diagnosis, fault analysis and eliminating methods realizes automatic control during the whole production. The production line is provided with the three-machine automatic control and balancing device to ensure balanced and reliable production.
1 The bottle washing machine adopts mechanical hands to clamp the bottles, suitable for vials of various specifications.
2 The water-gas spray needles adopt the reciprocating tracking insertion method for bottle washing, featured by excellent washing effect and energy saving. It is also provided with a device that prevents the needle holder from shaking to enhance the accuracy of the spray needle's insertion into the bottle and reduce the occurrence of needle breakage.
3 The water and gas pipes are totally separable from the spray needles, so that cross contamination is avoided and GMP requirements are satisfied.
The buffer block is installed before the bottle feeding screw of the bottle washing machine to protect the screw and reduce bottle breakage.
4 Bottle discharging is realized by the integral imported synchronous belt that is connected to the bottle pushing block to convey ampoules , a structure that ensures stable and reliable operation.
5 The oven adopts hot air circulation heating to achieve temperature and energy saving.
6 The oven is provided with the function of protecting against sudden power-off to ensure safe running.
7 The oven can be equipped with the circulation water cooling device that does not consume wind volume in the room, whilst reducing the risk of unbalanced differential pressure in the room and achieving good cooling effect;
8 The oven can be equipped with the differential pressure automatic balancing and regulating system to reduce the problems of deviation at the high temperature section caused by unbalanced differential pressure in the room and oven, temperature rise in the filling room, washing and drying room, and etc.
9 The oven is provided with DOP inspection ports (including inspection ports for wind pressure, wind speed and dust particles).
10 The cooling section in the oven can be provided with the sterilization function (selective for FDA).
11 The oven mesh belt can be equipped with the ultrasonic and CIP cleaning systems.
12 The oven cavity can be subject to all-round, multi-angled high pressure water washing.
13 The filling machine adopts the horizontal synchronous belt bottle conveying mode, featured by high speed, accurate bottle distribution and convenient replacement of parts.
14 The conveying plane where the bottle bottom is located has a certain distance to the work table, so as to benefit the passing of the 100-grade laminar flow and avoid turbulent flow of polluted liquid medicines.
15 The stoppling part of the filling machine adopts horizontal stopple conveying and horizontal round disc stopple suction, featured by convenient observation, easy feeding and high-speed stopple conveying.
16 The filling machine can be equipped with the ceramic pump, stainless steel pump and peristaltic pump.
17 The filling machine is provided with the functions of no filling in case of no bottle and no stoppling in case of no bottle.
18 The filling machine can be equipped with the servo filling system. (Delta, Mitsubishi, Schneider)
According to customer requirements, it can also be equipped with the following:
- Control system of such brands as Siemens, Schneider, Mitsubishi, Delta, and etc;
- Water pressure, air pressure, water temperature, ultrasonic strength, dust particles and wind speed online inspection, alarming, recording and printing systems;
- ORABS, CRABS, aseptic isolator system.
Machine consist of
|Filling and stoppering machine|
|Capping machine||light inspection machine|
filling dosage 2ml 12000(bts/Hr) (the procution capacity has low speed, middle speed and high speed, can be customized as per URS)
- Outer feature: outer material is stainless steel, dull polished. The whole line is good in appearance, easy to clean. It complies with gmp regulations and can be suitable for several bottle specs.
- Structure feature: water filling→ultrasonic wave coarsely washing→circulation water→circulation water + spraying WFI→compressed air→WFI→compressed air + spraying compressed air→tunnel oven preheating→high temperature sterilization→cooling→bottle feeding→filling→stoppering→(lyophilizer→cap-adding)→cap-sealing→labeling→to the next process
- Filling dosage feature: no dripping, no forming, and no spitting.
- Running feature: stable running, low noise, precise filling, low energy consumption, low bottle breakage ratio, high qualified product ratio.
- Performance feature: the whole line can single machine control or interlock control. Washing machine water and air ensure washing effect; tunnel oven high temperature ensure removing pyrogen; servo motor ensure filling precision;10-head capping machine ensure sealing effect; labeling machine pneumatic coding ensure labeling speed.
- Comply with GMP requirements. Contact part is made of SUS 316L and silicone rubber which is easy to clean and sterilize and without contamination.