In the realm of pharmaceutical manufacturing, precision and consistency are of utmost importance. As a leading provider of pharmaceutical equipment, Fillitech understands the significance of these details. This article delves into the principle of dosing discs, the parameters influencing the capsule-filling process, how to calculate capsule fill weight, and the capacity of capsule-filling machines.
Understanding Capsule Fillers and The Principle of Dosing Discs
Capsule fillers, such as the high-precision models offered by Fillitech, operate on a simple yet ingenious principle. The dosing disc, a vital component of the machinery, controls the volume of medication filled into each capsule. The key steps are:
- The disc rotates over the powder bed
- It picks up medication in its cavities
- Scrapes off the excess medication
The thickness of the dosing disc determines the volume of each cavity, thereby dictating the dosage of the medicine.
The standard Max dosing disc for each capsule:
At Fillitech, we provide the standard max thickness dosing disc, then adjust the thickness regarding to the powder charater,such as denisty,flubiltiy:
| 00size capsule | 23.8mm |
| 0size capsule | 23.8mm |
| 1size capsule | 20mm |
| 2size capsule | 17.5mm |
| 3size capsule | 16.5mm |
| 4size capsule | 14.5mm |
| 5size capsule | 10.5mm |
Determining the Parameters of the Capsule Filling Process
Several factors impact the capsule filling process:
- Dosing Disc Thickness: A key determinant of the dosage of the medication.
- Powder Characteristics: The flowability, compressibility, and bulk density of the medication powder can affect filling accuracy.
- Machine Speed: The speed of your Fillitech capsule filler can influence the process.
- Tamping Pressure: The amount of pressure applied can impact the compaction of the powder.
By carefully monitoring and controlling these parameters, consistent capsule filling can be achieved.
What is the relationship between dosing disc thickness, cavity volume, and dosage:
Determine the Desired Dosage: The first step is to identify the dosage you aim to achieve in each capsule. This is typically measured in milligrams (mg).
Identify the Bulk Density of Your Medication: The bulk density (BD) is a property of the medication itself. It’s defined as the mass of the powder divided by its volume, usually given in g/mL or g/cc.
Calculate the Required Cavity Volume: Once you have the desired dosage and the bulk density, you can calculate the volume of each cavity (V) in the dosing disc using the formula V = Dosage / BD. This will give you the volume in mL or cc.
Calculate the Dosing Disc Thickness: Given that each cavity in a dosing disc is typically cylindrical, the thickness (h) of the dosing disc (which equals the depth of the cavity) can be calculated using the formula h = V / (πr^2), where r is the radius of the cavity.
Calculating Capsule Fill Weight
Fill weight is a crucial factor in capsule manufacturing. It can be calculated using the formula: fill weight = bulk density x dosing disc volume. Here:
- Bulk density refers to the weight of the medication powder per unit volume
- Dosing disc volume pertains to the space in the disc cavity filled with medication
With this information, and by using high-quality Fillitech machinery, you can precisely calculate the fill weight.
The Capacity of Fillitech Capsule Filling Machines
The capacity of capsule filling machines from Fillitech varies greatly to cater to diverse manufacturing needs:
- Smaller bench-top models have a capacity of around 12,000 capsules per hour
- High-speed industrial machines can fill up to 200,000 capsules per hour
With Fillitech, you can choose a machine with a capacity that matches your production needs.
Conclusion
Mastering pharmaceutical manufacturing involves understanding various aspects of the process. With Fillitech’s top-notch equipment and this guide to choosing the right dosing disc thickness, understanding the capsule filling process, calculating fill weight, and recognizing the capacity of your capsule-filling machine, you’re well on your way to producing high-quality, consistent products. Whether you’re an experienced pharmaceutical manufacturer or a beginner, Fillitech and this guide are here to help you.
