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Effective washing is the summed effect of the mechanical action of the jet spray plus the chemical dissolving action of the dissolving water – enhanced by detergents and by temperature. Automated washers are increasingly used by the regulated pharmaceutical and bio-processing industries to assure a repeatable, validatable cleaning process.
There are two key design considerations:
- the geometry of the wash items (e.g. trays, glassware, change parts, containers);
- the nature of the contamination (e.g. Greasy, Aqueous, Proteinous)
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Typically stages include:
- Pre-rinse; hot water spray or cold for proteinous contamination. The wash water is recirculated to reduce consumption.
- Recirculated washes, with or without detergent(s), neutral, or alkaline to break down greasy contaminants followed by a neutralising weak acid wash.
- Multiple recirculated post-rinses, hot or cold.
- Final WFI rinse to displace residual wash water, with a low conductivity target.
- Drying by sterile filtered hot air
- Cooling, line purging.
Ultra-washers further add these enhanced process capabilities:
- Pre-steaming to remove gross contamination
- Pre-rinse with superheated water spray
- Drying by vacuum
- System SIP
Attention to detailed design is needed to minimise the carry-over of fluids between stages which would reduce effectiveness and increase the risk of cross-contamination between loads. This demands excellent free-draining, which leads to a requirement for all surfaces to be highly polished, sloped to drain, an absence of deadlegs and widely radiused chamber corners.
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