Ultrasonic Washing Ampoule Filling Machine with 1–20ml Size Range for Pharmaceutical Production

This ultrasonic washing ampoule filling machine combines cavitation cleaning with a full 1–20ml size range, making it the most flexible particle-control solution for pharmaceutical production. The ultrasonic stage delivers the cleaning power needed for injectable glass, while the quick-change tooling keeps the size range practical. Producers with diverse portfolios get one machine that cleans deeply and adapts to every ampoule size they run.

Producers with wide ampoule portfolios face a dilemma: deep cleaning requires ultrasonic washing, but ultrasonic modules are usually offered on machines with a narrow size range. Running 1ml and 20ml ampoules on the same line forces either two machines or accepting weaker cleaning for one format. Both options raise capital cost and complicate validation.

Ultrasonic washing effectiveness depends on the transducer field matching the ampoule geometry: a bath tuned for 1ml ampoules does not couple energy efficiently to a 20ml body. Manufacturers historically solved this by fixing the bath to one size range and selling separate machines. The tooling change problem also discouraged size flexibility, because the ultrasonic basket and washing nozzles were not designed for quick replacement.

This machine uses a segmented ultrasonic bath with adjustable transducer power zones, so the energy field is re-tuned per ampoule size through the PLC recipe system. The washing baskets, nozzles and star wheels are quick-release tooling, and a full size change takes about 35 minutes. Cleaning performance is verified per size at the factory, and the FAT includes particle tests on both 1ml and 20ml ampoules.

• Adjustable transducer power zones: ultrasonic field re-tuned per ampoule size via PLC recipes
• Full 1–20ml tooling set: quick-release baskets, nozzles and star wheels for every size
• 35-minute size changeover: recipe-based re-tuning plus quick-change mechanical tooling
• Verified cleaning per size: FAT includes particle tests on 1ml and 20ml ampoules
• Deep cavitation cleaning: removes particles down to 0.5µm from the inner wall
• Pharmaceutical-grade materials: 316L bath and WFI-compatible water paths

This machine fits pharmaceutical producers with diverse ampoule portfolios, such as multi-product antibiotic lines, herbal injection manufacturers with varied dosage sizes, and CMOs serving different clients' formats. It is also the upgrade path for plants replacing jet-only washers after foreign-matter inspection failures. The 1–20ml range covers the vast majority of commercial ampoule products worldwide.

R&D-to-pilot facilities use the machine's recipe system to replicate cleaning conditions across development batches and commercial production.

Confirm your particle control target before selecting the ultrasonic option: if your products routinely pass foreign-matter inspection, the standard jet-wash version saves cost. Second, list your actual ampoule sizes, because the tooling set price depends on how many sizes you need. Third, check whether your water system can supply the WFI rinse volume of about 1.5 m³/h at peak output. Finally, ask for particle test data from the FAT on your two most extreme sizes (typically 1ml and 20ml) to validate the cleaning claims.

Q: How does the segmented ultrasonic bath adapt to different sizes?

The bath is divided into independently powered transducer zones. The PLC recipe for each ampoule size activates the zones and power levels that match the ampoule's position and length, so energy couples efficiently whether the ampoule is 1ml or 20ml.

Q: Does changing size require replacing the ultrasonic bath?

No. Only the basket inserts and nozzle sets are replaced, which takes about 35 minutes including the filling and sealing tooling. The bath itself stays in place and is re-tuned through the recipe.

Q: What cleaning verification is provided?

The FAT includes light-obscuration particle testing on your ampoules before and after washing, with a target of fewer than 20 particles per ml above 10µm. We also provide a recommended periodic verification protocol for routine production.

Q: Can the machine wash ampoules with printed labels?

Yes, the washing process is compatible with printed ampoules. For laser-marked or ink-printed codes, we recommend confirming ink durability in the washing bath; most pharmaceutical-grade inks survive ultrasonic washing without fading.

Every machine is test-run with water and dummy ampoules for 72 hours before packing, and a sealed calibration report is shipped with the unit. The machine is wrapped in anti-rust film and secured in an export-grade wooden case with foam inserts, suitable for sea or air freight. We supply CE, GMP and ISO 9001 documentation, a 12-month warranty on parts, and lifetime remote technical support. On-site installation, operator training and IQ/OQ/PQ validation assistance are available on request.