KQCL Vertical Ultrasonic Washing Machine

Product Details

KQCL Vertical Ultrasonic Washing  Machine

This machine is mainly used for  washing of vials in pharmaceutical factories, it also can be used for washing  glass containers such as ampoules and oral liquid bottles.

This machine use vertical gyration  structure. It adopts the way of clamping and overturning bottles with  manipulator and the principle of ultrasonic cleaning and washing by alternant  jetting water and airflow to clean the containers one by  one.

The major characteristics:  circulation water, compressed air and WFI are using independent needle, without  cross contamination. Needles are inserted bottles for flush, there is no water  or air loss, saves energy, and has good washing effect. It can observe whole  washing process, convenient for operation and maintenance. For Series B washing  machine, an additional air flushing and silicone flushing stations are  designed.

Structures

Vials are inputted through conveying  belt, slide into the pool after infusing water, then are washed through  ultrasonic about one minute. The screw separates vials and sends vials to  lifting device. The screw is designed according to best curve, make vials  conveyed from screw to lifting device smoothly. Lifting device lifts vials  smoothly from water and conveys to manipulators of rotary drum. Manipulators  clamp vials and turn 180o, in order to enter following washing station. First  step, high-pressure circulating water flush the exterior wall of vials, then the  first group of needles insert into vial and flush circulating water, the second  group of needles flush circulating water, the third group of needles flush  compressed air, discharge residual circulating water. The fourth group of  needles flush inject water, the fifth, sixth group of needles flush compressed  air, discharge residual water at most in order to dry. Finally flush compressed  air to exterior wall of vials. Manipulator turnover vials and sent to output  device, then conveyed to tunnel or output plate through output starwheel. The  whole washing process is finished.

Infeed station

It adopts chain mesh belt, and the  height of belt can be adjusted, vial infeed is stable. We adopts numerical  control to make mesh belt, uniformity of mesh hole and smoothness of belt are  good. Conveyor belt size: 1300mm×360mm, main material SS304.  

Ultrasonic washing station  

It adopts the ultrasonic washing  method.

It is equipped with water spraying  device at vial infeed station. Vials are filled with water, then are sent to  rough washing tank, which can prevent vials from floating, and guarantee washing  effect.

Ultrasonic power is 600w, and can be  displayed. The power can be adjusted according to vial specification and status.  

The water temperature of tank is  heated by two 4.5kw electric heaters, there is temperature controller to control  and the temperature can be displayed, guarantees best washing temperature of  ultrasonic cleaning at 40-60℃.  

Conveying station  

Rough washed vials are sent directly  to the manipulators of the big rotary drum through screw conveyor and lifting  device, and are clamped at vial neck to enter fine washing.  

It adopts lengthen gradually  changing type screw, which is good for transfer of vials, and can reduce vial  falling, breaking, vial absence effectively.   

The installation surface of lifting  cam shaft，output wheel shaft and big drum  central shaft are formed in one time through large numerical control processing  center. It guarantees the balance level of axis and verticality to datum  surface, highly improves transmission precision and stability.  

Fine washing  station

The manipulators of the big rotary  drum structure turn the vials upside down, wash the interior side of vials by  three times of water and three times of air, and wash the exterior side of vials  by recycling water and compressed air each one time. Rotary structure; clamping,  turning over and transiting the vials by manipulators.

Cleaning Sequence: 

1. Recycling Water: vial interior +  vial exterior

2. Recycling Water: vial interior  

3. Sterile Compressed air: vial  interior

4. WFI: vial interior  

5. Sterile Compressed air: vial  interior

6. Sterile Compressed air: vial  interior + vial exterior

The flushing of WFI and compressed  air is interval type, on and off is controlled by pneumatic diaphragm valve. It  begins to wash when the needles are inserted into the inner side of vial, which  saves energy. 

Exterior Washing has two sets of  flushing devices for recycling water and compressed air, the flushing pressure  can be adjusted.

As for small mouth vial, we adopts  the newest vial mouth orientation patent technology, needles aim well to center,  have no friction to vial interior wall. The guide cover and guide plate adopts  separate structure.

We adopt the original central oil  feeding system. When feeding, the covers don’t have to be dissembled, and the  efficiency of oil feeding and lubrication is much better than oil feed by  operator. At the same time, it reduces pollution and labor intensity, which will  be good for realizing the sterile producing.   

Main bearings on the machine adopt  EZO bearing and IGUS bearing. These bearings have high precision and increase  the stability and service life greatly.

Water and air filtration and  conveying station

Equipped with pipe system for inner  water and air running. Unmovable circuits for water and air adopt stainless  steel rigid tubes, they were welded automatically with technology of no padding  and single side welded double sides shaped. They were connected according to the  flowing direction of washing medium from higher place to lower place, ensures no  residue. At the same time, it marks washing medium and flowing direction on  pipeline, meets the sterile producing requirement and standard of FDA and EU.  The movable tubes for water and air adopt Toyox brand, they meet the requirement  of medical sanitary level.    

Compressed air, recycled water and  WFI for flushing are filtrated through filter, flushed WFI are used as recycled  water through pump and filter, reduces water consumption. Compressed air and WFI  is filtrated through one grade 10 inch Wenzhou Boao filter, filtration precision  is 0.22μm, recycled water is filtrated through three cores Wenzhou Boao filter,  filtration precision is 3μm. It increases sampling point at rear end of filter  for sampling.

Diaphragm pressure gauge are adopted  to control the pressure of washing medium, when the pressure of washing medium  is lower than the rate value, the pressure gauge will send an order and the  equipment will stop automatically, and restart automatically after the pressure  back to normal. This structure meets the sanitary requirement.  

The 2 GAME pneumatic diaphragm valve  and 7 manual diaphragm valve, pneumatic control element of FESTO brand to  control the on-off of water and air, which saves water and air consumption and  decreases the cost. It meets the FDA and EU standard.

The needles are made by the special  technology invented by TRUKING of which structure is an integrated pipe of  SS316L material going to the end of needle holder, and welded by the automatic  welding machine. No dead angle exists and meets the requirement of sterile  producing.

Exhausting of steam

There is safety cover (made of  transparent polymethyl methacrylate) in washing part. It can bear high pressure  and high temperature and strong impact, whole cleaning process is visible. 

There is a steam exhausting port at  the fine washing station, but the buyer should connect machine with related  dehumidifying pipeline and fan. (300m3/h, 400Pa)

Outfeed station

Vials move out through star wheel.  It avoids vial breaking, meets aseptic production request.  

Single outfeed path and the vials  are sent to the tunnel directly. The vials are covered between exit of washing  machine and entry of tunnel, material of cover is polymethyl methacrylate.  

Control system

HMI：Proface, 5.7”, color screen.  

PLC：Siemens

Electric cabinet: together with main  machine and be airtight.   

Electric control panel: together  with main machine, and connected with the electric cabinet by wire. Equipped  with touch screen, emergency button, it can display the alarm, and reset by  manual operation.

Interlocking device: interlocking  with the downstream Sterilizing & Drying Tunnel and Filling & Stoppering  Machine to show the causes of fault, position of fault and simple solution.  

It is protected through 3 levels  password: operator, engineer and administrator.  

Key  Words:

Pharmaceutical Machinery, Pharmaceutical Engineering,  Pharmaceutical Equipment,
Packaging Machinery, GMP Machinery, Pharmaceutical  Industry, Pharmaceutical Technology

cGMP Service, cGMP Solutions, cGMP  Validation