Oral Liquid Filling and Capping Line (Washing, Drying, Filling and Sealing)

An integrated oral liquid production line is a complete, automated system that combines multiple manufacturing stages into a single, seamless workflow. It is designed to take empty bottles and produce a final, sealed product ready for packaging. The core processes typically include:

• Ultrasonic Washing: Deep cleaning the bottles.
• Sterilization & Drying: Using a high-temperature tunnel to ensure bottles are sterile and dry.
• Aseptic Filling: Precisely filling the bottles with liquid in a sterile environment.
• Capping & Sealing: Securely sealing the bottles to ensure product integrity.

Yes, absolutely. The entire production line is designed and manufactured in strict accordance with current Good Manufacturing Practice (GMP) standards. Key GMP features include the use of 316L stainless steel for all contact parts, an aseptic design to prevent contamination, and traceable, validatable control systems.

The production capacity for this line is highly flexible, ranging from 6,000 to 22,000 bottles per hour. The exact speed depends on factors such as the bottle size (from 5ml to 25ml), the viscosity of the liquid product, and the specific filling volume.

The line ensures an aseptic environment through a multi-layered approach. First, the ultrasonic washer and WFI (Water for Injection) rinse thoroughly clean the bottles. Second, the hot air sterilization tunnel uses high heat for depyrogenation. Finally, the filling and capping stations are protected under a Class 100 laminar flow hood, creating positive pressure with HEPA-filtered air to prevent any airborne contamination.

The system incorporates several advanced features to ensure high quality and minimize waste. Key performance metrics include:

• Filling Accuracy: A high-precision dosing system maintains an accuracy of ±0.5% to 2%.
• Low Breakage Rate: Gentle bottle handling ensures a total line breakage rate of less than 0.5%.
• High Sealing Integrity: The capping and sealing success rate is greater than 99%, preventing leaks.
• Smart Sensors: “No bottle, no fill” and “no bottle, no cap” functions prevent waste of product and materials.

Yes. The line is engineered for flexibility and can be configured to handle various bottle sizes within the 5ml to 25ml range. Switching between sizes requires a set of format-specific “change parts,” which are designed for quick and efficient changeover to minimize production downtime.

An integrated or “monoblock” line offers several key advantages over using separate, standalone machines:

• Smaller Footprint: It occupies significantly less cleanroom space.
• Guaranteed Compatibility: All modules are designed to work together perfectly.
• Single Point of Control: The entire line is operated from a unified HMI (Human-Machine Interface).
• Streamlined Validation: The validation process (IQ/OQ/PQ) is simpler and faster.
• Reduced Labor: Higher automation reduces the need for operator intervention.

The oral liquid production line consists of three core, seamlessly connected modules:

1. Vertical Ultrasonic Bottle Washer: For intensive, multi-stage bottle cleaning.
2. Hot Air Circulation Sterilization Tunnel: For drying bottles and removing pyrogens.
3. Filling and Capping Machine: For precise liquid filling and secure sealing in an aseptic zone.

This line is primarily designed for pharmaceutical oral liquid formulations. However, its high-precision, aseptic capabilities also make it ideal for other industries requiring sterile liquid filling, such as high-end nutraceuticals, veterinary medicines, and certain cosmetic products like serums in glass vials.

While exact requirements can be customized, typical utility needs include a stable power supply (approx. 72 kW, 380V, 50Hz), clean compressed air (35-80 m³/h @ 0.3-0.6 Mpa), and a source for fresh/purified water (0.6-1.0 m³/h @ 0.2-0.4 Mpa). The system also requires ducting for an exhaust air volume of 3,500-4,000 m³/h.