Linear Tunnel Type Washing Machine
High-throughput linear tunnel container cleaning system featuring ultrasonic pre-cleaning bath, synchronized multi-needle diving wash manifolds, and seamless direct transfer into continuous depyrogenation tunnels.
Description & Operating Principle
HMEC’s Linear Tunnel Type Washing Machine is the premier industrial cleaning solution for ultra-high-speed sterile filling lines, particularly for injectable vials, ampoules, and pharmaceutical glass infusion bottles. Operating on a continuous linear indexing conveyor mechanism, containers are fed from an unscrambling turntable into a multi-lane infeed chute.
The machine incorporates an optional high-frequency ultrasonic pre-wash bath that dislodges micro-particles and stubborn glass dust. Following the ultrasonic stage, inverted containers are securely transported across distinct washing zones via indexed stainless steel pocket carriers. Multi-station servo-driven needle manifolds dive synchronously into the container necks, delivering pressurized cycles of recirculated water, purified water, hot WFI, and HEPA-filtered compressed air. The linear continuous movement allows direct inline feeding onto the wire mesh belt of an adjoining depyrogenation sterilization tunnel without manual intervention.
Target Containers & Applications
Engineered for high-volume aseptic pharmaceutical and biotech production facilities:
💉 Sterile Injectable Vials
Tubular and moulded glass vials (2ml to 100ml) for liquid injectables, vaccines, and lyophilized powders.
🧪 Glass Ampoules (1ml to 20ml)
Open-funnel and closed-neck glass ampoules with ultra-fine multi-needle internal water and air jetting.
🏥 IV Infusion Glass Bottles
100ml, 250ml, and 500ml glass infusion containers requiring heavy-duty continuous multi-stage cleaning.
🔬 Dental & Ophthalmic Cartridges
High-precision dental carpules and ophthalmic dropper bottles requiring particulate-free sterile wash.
Pros & Cons Comparison
✅ Advantages (Pros)
- Ultra High Speeds: Multi-lane linear indexing supports speeds up to 350+ containers per minute.
- Ultrasonic Cleaning Power: Dislodges microscopic sub-visible particulate matter before water jetting.
- Direct Sterilizing Tunnel Link: Continuous linear outfeed eliminates buffer turntables and reduces contamination risk.
- Diving Needle Precision: Deep-reaching spray needles enter straight into narrow neck openings with zero rim contact.
- Modular Wash Zones: Highly customizable wash stations tailored to specific pharmacopeial standards.
⚠️ Considerations & Limitations (Cons)
- Longer Machine Footprint: Linear multi-zone layout requires a longer longitudinal cleanroom footprint.
- Dedicated Carrier Pockets: Switching between widely different container diameters requires interchangeable carrier pocket blocks.
- Complete SS 316L fluid path with sanitary tri-clamp connections and orbital welded piping
- Integrated ultrasonic pre-wash tank with piezoceramic transducers for particulate scrubbing
- Servo-synchronized diving needle manifolds for internal washing with positive centering
- Independent external washing showers for 360-degree outer container decontamination
- Dual recirculating SS 316 water tanks equipped with multi-stage centrifugal pumps and pressure gauges
- 0.22 micron HEPA filtered compressed air blow-off zone for moisture removal
- Direct integration with continuous hot-air laminar flow depyrogenation tunnels
- Siemens / Allen-Bradley PLC with touchscreen HMI for 21 CFR Part 11 electronic batch compliance
| Output Speed | 80 to 350+ Containers Per Minute (CPM) (Lane and container size dependent) |
|---|---|
| Container Range | Vials (2ml to 100ml), Ampoules (1ml to 20ml), Glass Bottles (up to 500ml) |
| Ultrasonic Power | 20 kHz to 40 kHz (Optional 1 kW to 2 kW piezoceramic transducer pack) |
| Washing Stations | 5 to 8 Sequential Internal Stations + 2 External Washing Stations |
| Washing Media | Recycled Water, De-mineralized Water, Fresh WFI, Clean Compressed Air, Pure Steam |
| Water Pressure | 2.0 to 3.5 Bar (Individual pressure regulators and gauges on each manifold) |
| Air Requirement | 4 to 6 Bar Clean, Dry, Oil-Free Compressed Air (20 - 40 CFM) |
| Material of Construction | SS 316L Contact Parts & Piping, SS 304 Outer Panels & Support Structure |
| Power Requirement | 415V / 3 Phase / 50 Hz (5.5 kW to 9.5 kW) |
Change parts for Linear Tunnel Washing Machines are modular and engineered for tool-less replacement within 25-35 minutes:
- Carrier Pocket Bars: Precision CNC-machined SS 316/POM pocket blocks tailored to container diameter.
- Infeed Track & Gate Assembly: Multi-lane infeed spacing rails and container separators.
- Needle Manifold Bars: Interchangeable spray needle arrays matched to container pitch and neck opening.
- Outfeed Transfer Pusher: Synchronized transfer fingers for outfeed onto the depyrogenation tunnel belt.
Q: How does ultrasonic cleaning benefit vial washing?
A: High-frequency ultrasonic cavitation produces microscopic vacuum bubbles that implode against the glass surfaces, dislodging stubborn particulate matter, glass dust, and electrostatic contamination that water sprays alone cannot remove.
Q: Can the linear washer connect directly to a depyrogenation tunnel?
A: Yes. The linear outfeed matches the speed and belt width of continuous laminar flow depyrogenation tunnels, creating an uninterrupted sterile vial processing line.
Q: What documentation is provided for pharmaceutical validation?
A: HMEC provides comprehensive validation documentation including DQ, IQ, OQ, FAT/SAT protocols, material test certificates (SS 316L MTRs), and calibration records.