Vials are important entities in the pharmaceutical industry. In such industries, hygiene and cleanliness are of utmost importance, and hence, the vials need to be cleaned before utilization. Due to awareness of health and hygiene maintenance, the need for Vial Washers have also increased. Since the production of manufacturing medicines is done in large amounts, the vial washing machines need to work at a rapid pace to meet up to the expectations of the medical industry. As a result, the need for automatic vial washing machines with different production capacity has also increased.
Vial Washing Machine
By cleaning the vials, its surface becomes free of any signs of impurity that could earnestly impair the product’s integrity. This is a first step that must be taken before the vial can be used.
The vial washing machine uses nozzles to wash the vials. Also, the machine has a brush procedure to eliminate dust from the vial’s exterior surface. This washing machine has air knives used to air-dry the vials once they’ve passed through the water while they were being cleaned.
Types of Automatic Vial Washers
Automatic vial washer has 3 types: rotary, linear, and batch washers.
Linear vial washing machines are familiar with pharmaceutical companies that require an excessive quantity of vials. These are colossal machinery, quite costly to run, and generally have a high cost of maintenance.
Batch washers function by washing vials on a rack and need an operator to fill and unpack the racks. It’s projected that approximately 75% of the microbial contaminant of laboratory equipment is due to humans. Therefore, if a high degree of hygiene is required, employing the use of batch washers isn’t the ideal option.
Rotary vial washing machines are standard for the high production rate of washed vials. Based on the washer’s size, a low average production can be 40 vials/minute for a minor laboratory or equipped with 400 (2ml) vials/minute for fast-moving automation used by large pharmaceutical companies.
Precautions for Vial Washing
Depyrogenation must be achieved when washing the vial. If this is not the case, impurities during the cleaning process lead to feverish reactions in animals and humans. Furthermore, negligence in removing all bacterial toxins like exotoxins and endotoxins results in several illnesses and diseases in the consumer.
Safety measure and cGMP (Current Good Manufacturing Practice) regulations have to be employed in the cleaning process. Foremost, the vials should be purified utilizing sterilization and depyrogenation tunnel.
In these tunnels, the vials are heated to a high temperature, which destroys most germs. Then the vials pass through a washing process, which additionally removes any process dirt or pathogens.
It’s essential to avoid human hand contact as it carries lots of pathogens, viruses, and bacteria. An automated washing machine averts most contamination. The vials and parts of the washer involved in the washing mustn’t come into contact with the atmosphere as filth, bacteria and other pollutants contaminate them. A sealed washing setting is of utmost importance.
The cleaning procedure has to be controlled cautiously to ensure sterile cleaning. The nozzles utilized in cleaning must penetrate the bottles and squirt the cleaning substances onto every part of the vial before, rinsing and dry out.
The containers used in storing washing agents have to be uncontaminated, thereby preventing contamination. Washing and drying must be performed in steps as prescribed by the cGMP.
Also, the materials that the cleaning parts are manufactured from must be resistant to corrosion by air, water, and the chemical contained in the cleaning agent. If these parts corrode, it can result in the vials containing a little number of metal fragments that can react with the medication and initiate contamination. These should be manufactured with high-quality stainless steel.