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Air-Over-Pressure Sterilizers

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Air-over-pressure (AOP) sterilizers are highly specialized autoclaves designed to sterilize loads containing sealed or semi-sealed liquid containers (such as vials, bottles, or ampoules) without causing them to burst or crack. During a normal sterilization cycle, the pressure inside the sealed container increases, and if the chamber pressure is rapidly released (vented), this internal pressure difference causes the container to fail. AOP technology counteracts this by injecting pressurized air (or another gas) into the chamber during the cooling phase. This air maintains an external counter-pressure that exactly matches or exceeds the internal pressure of the sealed containers, ensuring structural integrity while the temperature drops. AOP systems are mandatory for the terminal sterilization of final, sealed pharmaceutical products, ensuring both sterility and container stability, and are a cornerstone of GMP-compliant manufacturing.

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Specification

ParameterDetail
Sterilizer TypeHigh-End Industrial/Pharmaceutical
Key TechnologyPressurized Air/Gas Injection During Cooling
Load CompatibilitySealed Vials, Ampoules, Bottles, Blister Packs
Cooling MethodForced Cooling (External Jacketed or Internal Spray)
Pressure SourceIntegrated Air Compressor or External Gas Supply
ControlPrecision PLC Monitoring of Load and Chamber Pressure
ComplianceMeets GxP Standards for Terminal Sterilization
Chamber DesignFully Jacketed, Horizontal or Vertical Configurations

Application

The primary settings are pharmaceutical manufacturing plants, high-volume compounding pharmacies, and biotechnology facilities that perform terminal sterilization of liquid products. These units are typically installed as large, floor-standing, pass-through autoclaves within a cleanroom environment. They are used to sterilize critical loads like large batches of IV solutions, sealed injection vials, and eye drops. The precise control over the cooling profile (temperature and counter-pressure) allows for faster cycle times compared to passive cooling, significantly increasing production throughput while ensuring product quality. AOP is an essential process step for any manufacturer relying on terminal sterilization rather than aseptic filling, offering a higher degree of sterility assurance for sealed products.

Transaction Details

AOP sterilizers are major capital purchases. Payment terms involve a Letter of Credit (L/C) or structured T/T payments tied to design approval, manufacturing milestones, and final Factory Acceptance Testing (FAT). Shipping is via specialized heavy-duty freight under CIF/DDP terms. The price includes the complex air compression system and the full IQ/OQ/PQ validation package. Lead times are the longest for all categories (up to 6 months) due to design, manufacturing, and regulatory compliance requirements. Buyers must provide detailed utility specifications, including the required compressed air purity. The warranty covers the pressure vessel and the sophisticated control system. We require a mandatory site inspection before installation to ensure the facility meets the strict requirements for this complex equipment.

FAQ

  • Q: What is the risk if AOP is not used for sealed liquids?
  • A: The rapid venting of steam at the end of the cycle creates a pressure differential that can cause the sealed liquid containers (vials, ampoules) to explode or their seals to fail, leading to significant product loss and contamination risk.
  • Q: Is AOP only for pharmaceutical use?
  • A: While most common in pharma, AOP is also used in food and beverage processing (retorting) for sterilizing sealed canned or bottled products and in certain high-security research labs for sealed waste containers.
  • Q: How is the counter-pressure determined?
  • A: The counter-pressure is precisely calculated based on the maximum internal pressure the sealed liquid containers are expected to reach at the peak sterilization temperature, ensuring the external pressure always slightly exceeds the internal pressure.
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Wanrui Medical Instrument

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86-15728040705
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86-15728040705
86-18957491906