🧼 Module 1: Washing Systems
💧 Types of Washing Systems
Washing systems have varying structures and levels of automation depending on the needs of the production line. The most commonly used system types are presented below in a simple and understandable format:
Washing System Type | Explanation |
Manual Washing Unit | This is an operator-controlled washing system preferred in small-scale production or pre-validation cleaning processes. It typically operates using a hand nozzle and a compressed air/water line. |
Semi-Automatic Bottle Washer | This unit handles product transportation manually, but the washing cycle is performed by a timed, multi-station automated system. |
Fully Automatic Interior and Exterior Washer | This system, where packaging is fed via conveyor and its inner and outer surfaces are washed using PLC control, can be integrated into lines requiring high hygiene standards. It operates with multi-head nozzles that vary according to the packaging format. |
Rigid Format Washing Tunnel | This system performs high-speed, continuous washing and drying of small-volume products such as ampoules and vials, carrying out multi-stage washing and drying processes within a single tunnel. It is usually integrated with sterilization lines. |
Inverter Washing System | It allows for internal surface cleaning by inverting the bottle. It reduces the risk of particulate and dust residue in the pharmaceutical and food industries. It is presented with special transport mechanisms according to the product form. |
Pressure Nitrogen Washing Module | It is used especially in sterile or aseptic production lines. Particle cleaning is performed with pressurized N2 gas that leaves no chemical residue. |
These systems purify the inner and outer surfaces of bottles or vials by washing them with various liquids, removing particulate and microbial load. They typically operate in multiple stages, including processes such as air blowing, pure water washing, and WFI (water for injection) washing. Nozzle heads are custom-designed according to the packaging form, and the flow rate of the washing liquid is controlled by a precision valve.
Technical Specifications |
Explanation |
Washing Stages |
With 3 to 7 stations and programmable recipes. |
Number of Nozzles |
3-10 items (optimized per format) |
Liquid Options |
PW (15–25°C), WFI (70–90°C), compressed air, N2 |
Washing Pressure |
2.0 – 4.5 bar, digital pressure gauge controlled. |
Material Quality |
AISI 316L inner surfaces, orbit welded surfaces. |
Conveyor Type |
Servo motor driven chain/slide system |
Contact Time |
0.8 – 3.5 seconds (varies depending on product diameter) |
Flow Rate Control |
Line valve with flow regulator, adjustable from 1–5 L/min. |
Nozzle Movement |
Linear or rotary servo controlled. |
Liquid Tanks |
40 – 80 L double-walled, temperature-controlled container. |
Drainage System |
Automatic discharge and validation outlet line. |
Control Panel |
10″ HMI screen + PLC automation |
Traceability |
SCADA/MES integration infrastructure is ready. |
🌬️ Module 2: Drying Systems
🔥 Types of Drying Systems
Drying systems are offered with customized solutions according to different product structures and hygiene levels in the production line. The most commonly used drying technologies are listed below:
Drying System Type | Explanation |
Hot Air Dryer with HEPA Filter | It quickly dries the product surface with sterile hot air after washing. It is used in aseptic production lines. The HEPA filter prevents the risk of contamination. |
Nitrogen Gas Drying Unit | The drying process is carried out with inert gas (N2). It is preferred for products with a high risk of excessive oxidation. It has a heat-activated drying cycle. |
Air Knife Dryer | It removes water remaining on the outside of the bottle by scraping it away with high-speed air jets. It is commonly used in the food and chemical industries. |
Tunnel Type Conveyor Dryer | It is used in continuous flow production lines. It is preferred in high-volume production to increase drying efficiency. |
Vacuum Drying System (Optional) | It provides drying for heat-sensitive products using evaporation under vacuum. It is used in GMP-compliant production facilities. |
It ensures complete drying of products under sterile conditions after washing. It can be integrated with HEPA-filtered hot air, air blades, or a nitrogen blowing system. It is designed to minimize particle formation during drying. The product outlet temperature can be balanced with a cooling module.
🔥 Module 3: Sterilization Systems
🧪 Types of Sterilization Systems
Sterilization requirements are met using different methods depending on the sensitivity of the product and regulations. The most common system types are described below:
Type of Sterilization System | Explanation |
Steam Autoclave System | It provides sterilization with pressurized steam at a temperature of 121–134°C. It is commonly used for medical devices, glass bottles, and manufacturing equipment. |
Dry Heat Sterilizer | Sterilization is performed using hot air circulation at temperatures between 160–180°C. It is suitable for metal and heat-resistant materials. |
Gas Phase (EtO) Sterilization | Sterilization is performed at low temperatures using ethylene oxide gas. It is used for heat-sensitive products. |
Plasma Sterilization (optional) | Sterilization is performed using low-temperature hydrogen peroxide vapor and plasma technology. It is a modern and environmentally friendly alternative. |
Radiation Sterilization (outsourced) | This is done using gamma or electron beams. This system is usually performed externally and is preferred for large-scale mass production. |
It is used in products requiring terminal sterilization. This is usually achieved with autoclaves, sterile steam, or dry heat systems. In automated PID-controlled systems, temperature, pressure, and sterilization time are managed with full automation. |
Technical Specifications | Explanation |
Type of Sterilization | Autoclave (steam), dry heat (160–180°C), gas phase (EtO) |
Temperature Range | 121 – 134°C (steam), 160 – 180°C (dry heat) |
Time Control | PID controlled, 10 – 90 minutes |
Autoclave Type | Vertical or horizontal type, 316L inner shell, double jacket. |
Pressure Level | 1.1 – 2.5 bar (0.110 – 0.250 MPa) |
Sterilization Documentation | Thermocouple data logging, validation ports. |
Steam Source | External steam generator or line connection |
Container Capacity | 200 – 800 L loading capacity |
Security Locking System | Automatic door lock + pressure control sensor |
Energy Input | 380V 50Hz, 9–15 kW (for high steam demand) |
Cooling Cycle | Water + air circulation rapid cooling. |
Validation Compliance | 21 CFR Part 11 / GAMP5 compliance |