KVAP Ampoule linked unit consists of three separate machines, i.e. vertical ultrasonic wave cleaning machine, hot air circulating oven and ampoule filling and sealing machine. There are three operation areas, i.e. cleaning, drying and sterilizing, and filling and sealing. Each separate machine has its specific functions that can be realized correctly and reliably. They can be used for production in a separate or linked manner. The linked unit can finish about twenty production processes such as water spray, ultrasonic wave cleaning, washing, purging, drying and sterilizing, cooling, filling, nitrogen filling, sealing, etc. It is completely suitable for the production of ampoule injection. It is also the most ideal domestic injection production equipment that is mainly applied to the production of ampoule injection in a pharmaceutical factory's injection workshop.

1.   The linked unit is a new generation ampoule linked unit which is developed by our company on the basis of appreciation of foreign advanced and aims at the current situations of domestic ampoule injection. It features a more reasonable design structure, high automation, steady and reliable operation, high production efficiency and electromechanical integration. Its performance is up to the current internal advanced level. Therefore, it can replace imported products completely.

2.        The linked unit is divided into three operation areas, i.e. cleaning, drying and sterilizing, and filling and sealing. Each separate machine has its specific functions which can be achieved correctly and reliably. They can be used for production in a separate or linked manner. The unit can finish production processes such as water spray, ultrasonic wave cleaning, washing, purging, drying and sterilizing, cooling, filling, nitrogen filling, sealing, etc. It can be suitable for the production of ampoule injection completely.

3.        The linked unit uses advanced production process technologies such as advanced ultrasonic wave cleaning, alternative water/gas cleaning, hot air laminar flow drying and sterilizing, laminar flow purification, filling and drawing-sealing, etc. It is compact, safe, practicable, steady and reliable. It covers a small area and few factory buildings need purification, which complies with GMP requirements and reduces the use cost of air conditioning and purification and the construction cost of factory buildings.

4.        The linked unit is applicable to five easy-breaking ampoules (or specifications provided by the user). It has few standard parts and is easy to replace and adjust. It can enhance equipment utilization rate, reduce use cost and improve production efficiency.

5.        The linked unit uses PLC main control, variable frequency speed adjustment or HMI touch screen control technologies. The control system is steady, reliable, visual and convenient. The touch screen can indicate the operation status of each separate machine. The indication of water pressure, gas pressure, wind pressure, temperature, etc. of each control point, the indication of status and failure of each switch, and the self-diagnosis, analysis and troubleshooting of failure make the whole production process come up to automatic control level.

6.        Main parts and components of each separate machine of the linked unit use high-quality stainless steel material. Parts in touch with liquid drug use 316L stainless steel material, high-quality silicon hose or glass containers. They comply with GMP requirements completely. Plastic parts such as main pullers, railings, augers, etc. use imported materials. Main bearings use imported bearings.

7.        The control operation of the linked unit can be configured in an optional manner in accordance with special needs of the user. According to the situations of factory buildings, a bottle conveyance screen belt can be added in order to input and output ampoules automatically and avoid processes such as manual handling in the clean area, etc. Therefore, that no rotary discs pass in and out of the clear area during the whole process of production can be achieved. Both unpacking and bottle laying and finished products' putting into a disc are finished in ordinary areas. The cleaning and sterilizing process of rotary discs is simplified, and the cross pollution of people stream and material flow in the clean area is reduced, which makes the whole unit comply with GMP requirements further.

Flowchart:

Ampoule unpacking and installation → water spray → ultrasonic wave cleaning → bottle entry through the auger → bottle lifting through the cam → bottle clamping through the manipulator → bottle upturning through the manipulator→(bottle external wall: spraying and washing)→first circulating water washing → second circulating water washing → first compressed air purging → injection water washing → second compressed air purging → third compressed air purging→(bottle external wall: compressed air purging)→bottle upturning through the manipulator → bottle leaving through the puller → preheat → high temperate drying and sterilizing → cooling → bottle conveying → bottle entry through the auger → (nitrogen filling before filling) → filling → (nitrogen filling after filling) → preheat → drawing-sealing → count → finished products output

Ampoule Washing Machine:

1. Applicable specification:Ampoule: 1-20ML

2. Number of workpiece heads: 120

3. Rate of qualification of clarification of washed bottle: no less than 99%

4. Rate of damage of ampoule: No more than 0.5%

5. Production capacity:500 bottles/min

6. Electrical capacity: 17.5KW

7. Water consumption: 0.9m³/hr

8. Gas consumption: 65m³/hr

9. Overall dimensions (L*W*H): 2099*2248*1119MM

10. G.W.: 2000KG

Hot air circulating oven

Applicable specification: 1-20ml ampoule bottle

Production capacity:  500 bottles/min

Effective width of conveying belt: 620mm

Sterilizing temperature: 320°C adjustable

Electrical capacity: 51kw among which electric heating accounts for 43kw 

Overall dimensions: 4,300*1,750*2,350mm

Air cooling type                                   Air exhaust rate: 4,100mm³/h

Temperate at the bottle output outlet: ≤40°C

Water cooling type    water consumption: 3,000kg-6,000 kg/h (inlet water temperature is less than 8°C)

Temperate at the bottle output outlet: ≤25°C

N.W.:                              3,000KG

Ampoule filling and sealing machine:

a. Ampoule specification:                                                                         1-20ml

b. Output:                                                                                                     8,000-30,000 bottle/hr

c. Gas consumption                                                                                   600L/h (2-3*104Pa)

d. Oxygen consumption:                                                                           200L/h (2-5*104Pa)

e. Electrical capacity:                                                                                2.2kw

f. Overall dimensions of complete machine:                                       L*W*H: 3,447*1,266*1,326mm

g. N.W.:                                                                                                         2,500KG