Vials are practical containers used for storing and transporting liquids or powders such as medications, serums, vaccines, and chemicals. They are typically made from chemically inert borosilicate glass or plastic. To preserve the sterility and stability of the contents, vials are sterilized using vial washing machines. This process aims to remove particles and contaminants both inside and outside the vials. After cleaning, the vials are sterilized to eliminate microorganisms. The drying process of the vials, after washing and sterilization, takes place in clean rooms maintained by climate control units and dehumidifiers, which ensure temperature and humidity stabilization. During the drying process, dehumidifiers keep the relative humidity level low, facilitating water evaporation and product drying.
When the vials are ready for filling, liquid is filled into the vials using vial filling machines, and the products are transferred to the lyophilization unit. This three-stage process, also known as freeze drying, is used in the pharmaceutical and food industries. The liquid-filled vials are placed in an autoclave, where the temperature is reduced to quickly freeze the products, causing the water to crystallize. In the second stage, the frozen products are subjected to drying under vacuum. The products are brought to the sublimation point of water under negative pressure, where the frozen water (ice) transitions directly from solid to gas phase. The controlled heating of the product accelerates the evaporation of ice. However, the temperature must be carefully increased; otherwise, the product's stability and pharmaceutical efficacy will decrease.
After the lyophilization process is completed, the powders inside the vials are so hygroscopic that humidity becomes a critical issue before sealing the vials. In processes not conditioned by chemical dehumidifiers, the powder components inside the vials tend to clump even at low humidity levels. At this stage, the dry air supplied by silica gel rotary chemical dehumidifiers into the clean room makes it difficult or sometimes impossible for the component inside the vial to dissolve. In processes where industrial rotary dehumidifiers are not used, the product's shelf life is significantly reduced, and it becomes less effective for patients. Therefore, using industrial silica gel rotary chemical dehumidifiers with low dew point air production during the vial sealing stages is crucial for maintaining process integrity and hygienic conditions.
We as NKT – Humidity Control Technologies, our expert engineering team provides the best silica gel rotary industrial dehumidifier solutions for vial production, filling, and packaging rooms in pharmaceutical manufacturing. We offer energy-efficient, high-performance solutions.
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