The automatic high-speed hard gelatin capsule filling machine contains several different parts, such as the mechanical system, electrical system, pneumatic system driving system, or hydraulic system.In this article you can learn 20 important parts of the capsule filling machine,it is very useful for you to learn the knowledge.
Capsule Hopper
The capsule hopper serves as a storage unit for all capsules slated for filling. It is constructed from a stainless steel container, which can adopt a cubic, cylindrical, or conical form.
A hopper may also feature a gate to regulate the volume of capsules that are directed to the filling unit. This gate allows for precise control over the filling process, ensuring optimal efficiency and accuracy.
Capsule Separation Station:
This station ensures that the capsules are correctly oriented before they are going to the next step. Then the capsule can easily go into the segment and separate the capsule cap and body by vacuum. It’s a crucial step in maintaining the integrity of the capsules and ensuring a smooth filling process.
Powder Hopper with Screw Feeding
The powder hopper is used to powder storage. There are many different powder feeding system for capsule filling machine, but the screw feeding type is mostly used in the market,it is suitable for many different powders, and you can need to adjust the screw pitch according to the requirement.Then it feeds the material into the dosage disk, ready to be filled into the capsules.
Pellet Feeding System
Some capsules need to fill pellets or granules,so it require the pellet feeding system, it is different with the powder feeding system, there is no dosing disc and tamping pin, as the material with better fluidity,so it uses a volume dosing system to fill the pellet.
Powder Dosage Filling Device
It contains the dosing disc and tamping pin, dosing disc is used to keep each capsule is filled with a consistent amount of material. tamping pin compresses the powder into the capsule body. This ensures that the material is packed tightly and securely within the capsule. You can adjust the dosing disc thickness and tamping pin position to get the precise filling weight.
Complete Closed Rotary Turret
First and foremost, the rotary turret of an automatic capsule filling machine is completely enclosed. This design feature is crucial as it keeps the moving parts of the machine free from dust, ensuring the purity of the capsules and the longevity of the machine. This practice aligns with the manufacturing guidelines recommended by the Current Good Manufacturing Practice (cGMP) regulations.
With the fully enclosed rotary turret system, the automatic capsule filler machine efficiently orients the capsules into the turret. A significant number of encapsulating machines employ a rotary rectification system to achieve this. This system ensures that the capsules are correctly oriented and ready for the filling process.
As the capsules move to the blocks containing cups, any excess powder or pellets are redirected back to the hopper. This process ensures that no material is wasted and that the capsules are filled with the correct amount of material. During this process, these machines utilize a continuous motion for the closing action. This continuous motion ensures a smooth and efficient operation, reducing the risk of errors or malfunctions.
The design of the automatic capsule filling machine’s turret plays a significant role in its operation. It determines the ease of validation and the degree of versatility for dosages. A well-designed turret can accommodate a variety of dosage types and sizes, making the machine versatile and adaptable to different encapsulation needs. This adaptability is crucial in today’s pharmaceutical industry, where the demand for different types of capsules is constantly evolving.
Mechanical Drive System
The design and architecture of an automatic capsule filling machine give rise to a variety of movements – linear, rotary, or oscillatory – contingent on the specific design of the mechanical drive system. This system is the lifeblood of the machine, powering all its moving components and ensuring its seamless operation.
In a capsule filling machine, all moving elements are dependent on this mechanical drive system. This system typically comprises mechanical motors that generate motion, propelling the gears and conveyor systems that transport the capsules through the machine.
In today’s sophisticated manufacturing setup, all mechanical drives, including drive gears and conveyor systems, are fully enclosed. This design feature keeps them shielded from dust, ensuring the purity of the capsules and the longevity of the machine. It aligns with the manufacturing guidelines recommended by the Current Good Manufacturing Practice (cGMP) regulations.
For an automatic capsule filler, a Programmable Logic Controller (PLC) system governs the mechanical drives. This advanced control system ensures accuracy and consistency in the powder filling process. It allows for precise control of the machine’s operations, reducing the risk of errors and ensuring a high-quality output.
In general terms, all mechanical drives in an automatic capsule filling machine include the main drive, which powers the overall operation of the machine; the hopper drive, which controls the movement of the capsules and the filling material; and the vacuum pump and motor drive, which assist in separating the capsule bodies from their caps and in ejecting the filled capsules. Each of these drives plays a pivotal role in the operation of the machine, ensuring that it functions efficiently and effectively.
Lubrication System
A fully automatic capsule filling machine is a complex piece of equipment with numerous moving parts. Regardless of whether you choose a dosator or piston encapsulator, it’s essential to maintain these moving parts to ensure the machine’s longevity and efficiency.
One of the key maintenance tasks is lubrication. Moving pistons and other mechanical parts need to be regularly lubricated to reduce wear and tear. This not only extends the lifespan of the machine but also ensures a clean and efficient ejection of the filled capsules.
Modern automatic capsule fillers are equipped with an automatic lubrication system. This system lubricates the tamping and dosing discs, ensuring efficient plug injection. By reducing friction in the sliding components, the automatic lubrication system enhances the machine’s performance and reduces the risk of mechanical failures.
In most automatic encapsulation machines, a thin layer of oil lubricates the ribbon during both the sealing and filling processes. This lubrication ensures a smooth operation and prevents the capsules from sticking to the machine.
The latest models of automatic capsule fillers come with advanced lubrication systems that include fine filters. These filters ensure that the lubricant is clean and free of any particles that could interfere with the machine’s operation.
Common lubricants used in these machines include digestible mineral oil, Miglyol 812, and fractionated coconut oil. These lubricants are safe and effective, ensuring smooth operation without compromising the quality of the capsules.
An automatic encapsulating machine with a centralized lubrication system is a worthwhile investment. This system ensures that all moving parts are adequately lubricated, extending the lifespan of the machine and reducing maintenance costs. By choosing a machine with a centralized lubrication system, you can ensure that your automatic capsule filler will continue to operate efficiently for many years to come.
Safety Sensor System:
There are many sensors for the equipment, to ensure the machine running smoothly and operator safty.
A capsule hopper might be equipped with dual-level sensors. One sensor is dedicated to low-level sensing, while the other is designed for high-level sensing. Depending on the capsule level, the machine will automatically initiate the loading of empty capsules into the capsule filler hopper. Alternatively, it may deactivate the automatic encapsulator in the event that the capsule hopper is devoid of capsules.
the capsule hopper sensor, it can automatic control the powder feeding or stop feeding, when there is enough power or package of powder.
the door sensor, it can keep the operator safety, when the upper door or lower door open, machine will alarm and stop.
the lubrication sensor, then there is package of lubricate oil, machine will stop and also alarm, then it can keep the machine for long time use.
PLC and Touch Screen Control System
A fully automatic capsule filling machine is outfitted with a SIEMENS Programmable Logic Controller (PLC). This advanced control system guarantees reliable and consistent operation throughout the entire encapsulation process. It’s a testament to the machine’s superior design and the industry’s commitment to leveraging state-of-the-art technology.
Furthermore, these encapsulating machines feature an intuitive Human Machine Interface (HMI) in the form of a touch screen. This interface allows operators to effortlessly control and monitor the machine’s operations. The PLC and touch screen control system are housed in an electric control box, a critical component of the automatic capsule filler.
The HMI, or touch screen control interface, is just one of several control elements in an automatic capsule filling machine. Other control elements include:
Micro-electric current control, which safeguards the machine from overload. This safety feature ensures that the machine operates within its capacity, preventing damage and ensuring its longevity.
Emergency stop and vacuum gauges for capsule separation. These features provide additional safety measures, ensuring that the machine can be quickly halted in case of an emergency and that the capsules are correctly separated.
Intelligence mold control, which allows for precise control over the filling process. This feature ensures that each capsule is filled accurately and consistently.
These automatic systems allow for the uploading of all instructions that will operate the machine into the PLC’s microprocessor. This coded program ensures that the machine operates according to the specified parameters. Through the HMI, users can monitor and adjust the automatic capsule filler via the touch screen.
The control system is integrated in such a way that the machine can operate efficiently with minimal human intervention. This reduces labor costs and boosts the machine’s efficiency. While a fully automated control system is standard in fully automatic capsule filling machines, it can be an optional feature in semi-automatic models, providing flexibility based on the specific needs of the operation.
Motor
Fillitech use SEW motor from Germany,very famous brand.
Automatic Capsule loader
Automatic Powder loader
It can automatic transfer the powder into the capsule filling machine, can save time and laor cost.
Capsule Polishing Machine & Sorter
It can remove the empty capsule and half filled capsule to keep the good products into the next step
Metal Detector
It ensures the safety and quality of the capsules. It is designed to detect any metal contaminants that may have inadvertently entered the product during the manufacturing process
Dust collector
It can remove powder leakage and keep the working area clean .
Conclusion
Indeed, comprehending the most critical components of an automatic capsule-filling machine is essential when investing in new equipment. This understanding can assist you in making an informed decision, ensuring you select a machine that caters to your specific requirements.
FilliTech, a prominent manufacturer in the industry, provides comprehensive manuals with their automatic capsule fillers. These manuals offer valuable insights into the specific design and operation of their machines. By referring to these manuals, you can gain a more profound understanding of your FilliTech machine, enabling you to operate it more effectively and maintain it appropriately.
Whether you’re a seasoned veteran in the pharmaceutical industry or a novice, FilliTech’s automatic capsule filling machines and their detailed manuals are invaluable resources. They not only assist you in understanding the key components of the machine but also guide you in optimizing its performance for your specific encapsulation needs. Trust FilliTech to provide high-quality, reliable, and efficient solutions for all your capsule filling requirements.
