AKCA series vertical ultrasonic washing machine

Cleaning process: circulating water →circulating water →compressed air →water for injection→ compressed air →compressed air, good cleaning effect, prevent cross-contamination, totally meet the requirements of aseptic production.

Selection of components (1): Non-moving water and gas pipelines are made of 316L stainless steel pipe, according to the new technology of fully automatic welding of one-sided welding and two-sided forming without filler, the internal polishing of pipelines is processed, and endoscope inspection is used to ensure the smoothness of the internal pipelines. Fully meet the requirements of aseptic production, each pipeline welding joint can provide welding records. Compliance with FDA and EU standards. It is more in line with the new GMP standard of China.

Component selection (2): Hygienic German Gemu pneumatic diaphragm valve, manual diaphragm valve, Taiwan AIRTAC pneumatic component, control water and gas on-off, the switch valves are made of AILI316 material, diaphragm is made of PTFE or EPDM , which can save water and gas consumption and reduce operating costs while ensuring the cleanliness of liquid medicine. It conforms to FDA and EU standards, and is more in line with China's new version of GMP standards.

Selection of Components (3): Water and air hoses in moving parts meet the requirements of medical hygiene level, and can withstand pressure of 1.5 Mpa (equipment water pressure generally does not exceed 0.3 Mpa), which greatly improves the service life. The configuration is similar or equivalent to the similar structure of European products.

Selection of components (4): Air-water filtering and conveying station is composed of filters, pressure gauges, diaphragm valves, pumps, water tanks and water pipelines. The equipment only needs external injection water and compressed air, and the system can automatically complete the air-water conveying and filtering.

Component selection (5): The equipment is equipped with a circulating water pump with a lift of 40 meters and a power of 2.2 kw. Its main material is 304 stainless steel.

Monitoring method of cleaning process: independent spray needles are used for three kinds of media during cleaning. Each group of spray needles fixes only one cleaning medium to complete a washing station to prevent cross-contamination. Diaphragm pressure is used for monitoring. When the pressure of water and air is lower or higher than the limit value, it can automatically alarm and stop the machine to ensure the cleaning effect and safety.

1^st Improvement measure to comply with the New GMP Standard: With the original centralized oil supply system, there is no need to remove the cover to refuel, and the effect of oil supply and lubrication is much better than that of manual grease injection. At the same time, it reduces pollution and labor intensity, which is more conducive to the realization of aseptic production requirements.

2^nd Improvement measure to comply with the New GMP Standard:All water tanks are manufactured according to the requirement of no sanitary dead corner, i.e. the annular tank adopts the integral rolling forming technology with large rounded corners, the lower tank adopts the stamping and re-welding forming technology with large rounded corners, the upper tank adopts the transitional welding forming technology with rounded corners, and there is no sanitary dead corner, which fully meets the requirements of aseptic production. It meets the standards of FDA and EU and meets the requirements of the new version of GMP in China.

3^rd Improvement measure to comply with the New GMP Standard:The spray needle is manufactured by a unique process invented by HighFine Company. Its structure is a 316L pipe directly reaching the top of the spray needle seat, which is welded by an automatic laser welding machine. No hygienic dead corner, in line with the requirements of aseptic production.

4^th Improvement measure to comply with the New GMP Standard: The connection of hose joint is changed from clamp thread fixing to quick-fit clamp with no dead corner. It meets the requirements of the new version of GMP in China.

5^th Improvement Measure to Comply with the New GMP Standard: The whole cleaning part is equipped with a plexiglass protective cover, pressure, temperature and impact resistance, and the cleaning process is transparent and visible. It meets the requirements of the new version of GMP in China.

1^st control measure of broken bottle rate: The lengthened gradual winch is used to prevent the bottle from pouring, crushing and missing at the bottle feeding part, and to facilitate the bottle handover. There is a stainless steel mandrel in the center of the winch, which is cast by integral casting technology. It will not produce hygienic dead corner (avoiding drilling holes in the center of the winch, then inserting the mandrel into the central hole). Because of the gap between the mandrel and the central hole of the winch, there will be hygienic dead corner in the process and operation of the winch, which is not easy to deform. Thus, the rigidity and service life of the winch are enhanced. Even if the water temperature is higher in the water tank, the winch will not produce thermal deformation and bend, thus improving the stability of the equipment.

2^nd control measure of broken bottle rate: With the patented technology of bottle orientating, the spraying needle has  a good centrality, and there is no friction with the inner wall of the bottle, and no glass chips and metal particles are produced. The guide sleeve and guide plate adopt separate structure, and the guide sleeve can be replaced separately. The guide sleeve adopts macromolecule material, which has good wear resistance, long service life and greatly reduces the maintenance cost.

3^rd control measure of broken bottle rate: The manipulator chuck is made of imported modified polyurethane material, which has long service life, good elasticity, no bottle damage, good wear resistance and no falling off.

4^th control measure of broken bottle rate: The overturning telescopic cam adopts the integral spatial combination cam structure, and the bearing which realizes the telescopic motion is placed in a closed ring with no radial runout and axial movement. Therefore, the manipulator runs smoothly, and the spraying needle has good neutrality.

5^th control measure of broken bottle rate: The lifting cam and the turning cam are made of 40Gr steel material. The material is first tempered during processing, and then roughed, and then subjected to high frequency quenching. Finally, the CNC machining center with imported ultra-high speed (12000 rpm) is used, which enhances the machining accuracy of the cam and improves its wear resistance and service life.

6^th control measure of broken bottle rate: The ampoule bottle is made of advanced synchronous belt technology, and the bottle is pulled out with the synchronous toothed belt to avoid broken bottles and meet the requirements of aseptic production.

1^st process improvement measure：The transmission of the large drum adopts the offset edge transmission driving mode, and the transmission shaft and the bearing shaft are separated. Compared with the traditional worm and gear center transmission, the cumulative error of the tracking mechanism is greatly reduced. The latest patented technology of Highfine : Rotary drum swing frame and drum adopt split structure. Compared with the traditional overall structure of the drum, it is only necessary to remove the swing frame when repairing or changing the copper sleeve. It is no need to disassemble and debug the integral drum, and the inspection is quick and easy to debug. Therefore, the equipment runs smoothly and the tracking accuracy is high.

2^nd process improvement measure：The chain mesh belt is used to avoid the deviation and crawling of the net belt; the long mesh belt transfer method is adopted, and the height of the mesh belt is adjustable, which reduces the frequency of the upper bottle, reduces the labor intensity of the workers, and It is conducive to the increase of production and the stability of bottle feeding.The only domestic control system using digital control network, the mesh uniformity and mesh belt flatness is optimal, and the mesh belt frequency control, the stability of the bottle feeding is greatly improved.

3^rd process improvement measure：The main drive shaft adopts imported special drive shaft, which adopts advanced processing technology and hard chromium plating on the surface, which greatly improves the overall running performance, stability and service life.

Latest improved structure of equipment：The original inner gear drives the motion of the large rotary disc, which is supported on the plane of the telescopic large cam by 10 ball bearings. The plane of the telescopic cam is easy to wear. Balls are easily damaged and difficult to replace. Now a whole customized thrust centripetal ball bearing is used to drive the large revolving disc movement. The telescopic cam has no wear and tear, long service life, especially high running accuracy and good stability. It reduces the runout and shaking of the telescopic manipulator, thus reducing the probability of bottle breaking.

Old Structure

ol New Structure

Monitoring measures for the cleaning process: It adopts advanced PLC and programmable man-machine interface control system to control more effectively and fully. It can automatically stop when there is a fault, and display the fault location. At the same time, it can realize the joint control of the working condition with the subsequent process machine. Moreover, it can carry out man-machine dialogue with the machines in the follow-up work area to effectively transmit information and ensure the effective linkage operation of each single machine, and at the same time protects the machine. If there is a failure at the filling and stoppering machine, the cause of the failure is displayed on the man-machine interface, and The automatic command pauses the bottle feeding.