What is the difference between a rotary gripper and an external vial washing machine?
A rotary gripper washer holds each vial by the neck and performs internal + external washing with WFI final rinse. It is used for bulk unsterilized vials feeding a depyrogenation tunnel. An external washer only cleans the outside with brushes and spray jets — used for pre-sterilized RTU vials or coarse pre-wash.
What is the typical washing cycle on a rotary gripper washer?
An 8-station cycle: inversion, internal pre-rinse, internal recirculated wash, internal purified water rinse, internal WFI rinse, external spray, HEPA-filtered air blow-off, re-inversion. Total cycle time 8-14 seconds per vial.
How much WFI does the machine consume per cycle?
For a 10 ml vial on an 8-station machine, expect 5-8 ml of WFI per vial (4-6 ml internal + 1-2 ml external). At 200 VPM, that is 60-95 L/hour. A recirculation-recovery loop on the pre-rinse stages reduces WFI consumption by 30-40%.
Can the washer feed directly into a depyrogenation tunnel?
Yes. Rotary gripper units are designed for inline tunnel integration. Washed, WFI-rinsed, and air-blown vials are conveyed directly into the tunnel at matched speed and pitch, with no operator handling between wash and depyrogenation.
What validation documentation is supplied?
DQ, IQ, and OQ protocol templates; MTCs for SS 316L contact parts; surface roughness reports; calibration certificates; FAT report; cleaning validation guide covering swab recovery, rinse sampling, and endotoxin testing per USP <85>.
How do you handle vial breakage inside the machine?
Breakage in a well-tuned rotary gripper washer is below 0.1%. The gripper mechanism uses a soft polymer insert and a cam profile that controls clamping force. If a vial breaks, glass falls into a sloped tray and is flushed to drain; a broken-vial sensor stops the machine and alarms the operator.
What vial sizes can the machine handle?
Standard configurations cover 2 ml – 100 ml tubular glass vials (ISO 8362-1), 14-52 mm diameter, 30-115 mm height. Custom grippers for non-standard formats (moulded glass, infusion bottles up to 500 ml) are available.
What utilities does the machine require?
230V/415V AC 3-phase; 4-6 bar oil-free compressed air; purified water (USP <645>) at ≥ 600 L/h; WFI (USP <1231>) at ≥ 100 L/h; HEPA-filtered air for the blow-off station.
Is the machine suitable for pre-sterilized RTU vials?
For RTU vials, an external washer is usually sufficient — the inside is already sterile and pre-siliconized. Many customers pair an external washer with a nest de-bagger feeding directly to filling.
What is the difference between vial washing and ampoule washing?
Ampoules are sealed, so only the outside is washed. Vials are open-mouthed and require both internal and external washing plus depyrogenation before filling.
Do you export vial washing machines outside India?
Yes. As a vial washing machine exporter based in Ahmedabad, Gujarat, we ship to 25+ countries including USA, UK, Germany, Brazil, Mexico, UAE, Saudi Arabia, Bangladesh, Sri Lanka, Nepal, Afghanistan, Egypt, Kenya, Nigeria, South Africa, Vietnam, Philippines, and Indonesia.
What after-sales support do you offer?
We provide 1-year comprehensive warranty, lifetime remote support via video call / TeamViewer / WhatsApp Business, on-site service across India and abroad, AMC options with preventive maintenance and recalibration, and spare parts kits shipped within 24-48 hours globally from regional warehouses. Standard delivery: 6-8 weeks for standard machines, 8-12 weeks for custom configurations. Installation and validation typically add 2-3 weeks on site.