Capsule filling machine is a vital equipment in Pharmaceutical companies, health care product factories, hospital preparation rooms,as it can fill the exact weight of medications into the different capsule types. The benefits of the capsule filling machine include improved efficiency, accuracy, and reduced contamination risks. In this article, I will introduce different types of capsule filling machines, their key components, benefits, and factors to consider when choosing a capsule filling machine model and capsule filling machine supplier.
Three Normal Types of Capsule Filling Machines
A. Manual Capsule Filling Machines
It requires people to operate at every stage of the capsule filling process,such as separate the capsule body and caps, filling the power or granule into capsule,the speed is lower, suitable for small capacity without high product requirements and R&D use.
B.Semi-Automatic Capsule Filling Machines
It is automatic for some steps during the capsule filling process, such as capsule separation and powder filling. The operator is only responsible for loading and unloading the capsules and monitoring the process. These machines are suitable for medium-scale production and offer a balance between manual and fully automatic machines. It is Higher filling accuracy and production speed compared to manual machines.
C.Automatic Capsule Filling Machines
It is fully automatic for all the capsule filling process, including capsule separation, powder filling, capsule closing. Only one stuff is enough for one or two capsule filling machine.It is very suitable for medium to large-scale production.such as from min 200capsule per min to max 6000capsule per min.But the cost is also high and require more time for maintenance. Now most pharmaceutical factory require the automatic capsule filling machine.
The Key Components of Automatic Capsule Filling Machines
A. Capsule hopper where to fill capsule into the machine
B. Powder hopper where to fill the powder into the machine
C. Capsule magazine where to make the capsule aligned before go to the next step.
D. Capsule separate station to open the capsule caps and bodies
E.pellet filling station,it is used for pellet filling for capsule
F.Dosing station,to adjust the the powder filling weight for capsule
G.Reject station,to reject the unopen capsule
H.capsule closed station,after filling the powder, then closed the capsule cap and bodies.
I.quality capsule ejection, eject the quality capsule into the product bins.
J.cleaning station,to clean the power from the segment for the next step
K.Electric control cabinet,where to control the machine,such as speed,maintenance,to show the information on the screen,such as all parameters
L.Vacumm pump,provide the vacuum to open the capsule bodies and caps.
The Benefits of fully automatic Capsule Filling Machines
Improve productivity:
An automatic capsule filling machine can fill a large number of capsules in a short time, so it can increase production capacity and efficiency compared to manual or semi-automatic machines.Max speed can up to 6000capsule per min.
Enhanced Accuracy and Precision:
Automatic capsule filling machines are designed to ensure that each capsule can be filled the exact precise weight of medication and reduce the operate to involved, which helps minimize the risk of medication errors and ensure consistent quality across all capsules.
Reduced Labor Costs:
With a high level of automation, automatic capsule filling machines require only one operator to operate, which helps to reduce labor costs during the capsule filling process.
Lower Contamination Risk:
Due to the closed working of the automatic capsule filling process, no need stuff to load the power and capsule into the machines,so it can reduce the human involvement, then to reduce the risk of contamination that may occur during manual handling of capsules and medication.
Application:
It is suitable for a wide range of capsule sizes and types,as well as various fill materials, such as powders, granules, and pellets. Different types of capsule size requirements, from 00#to#5, and the speed is also adjustable, from min 100capsule for lower speed requirements to 2000capsule for high-speed requirements. One machine to meet different requirements
GMP Standard:
Automatic capsule filling machines are often designed to meet the current GMP standards for safety, cleanliness, and quality control, which helps ensure that manufacturers stay compliant with industry regulations.
Reduced Downtime:
Automatic machines often come with advanced features like automatic fault detection and self-diagnosis, which can minimize downtime and the maintenance process.
CFR PART 11
As the machine use PLC control and inverter, so it can add the Electronic signature Electronic record which meet the CFR PARTS11. This is the high-level pharmaceutical factory requirements,such as EU market, US market. It also can connect the the Scada system which to meet the online monitoring and control
How to choose the capsule filling machine models
Production Capacity and Speed Requirements:
Regarding the whole years’ production plan,5 working day per week,8 hours per day, such as the whole year’s production is 260000000capsule, then we can use 26000000/12month/22day/8hours/60mins= 2000capsule per min, so we can choose the NJP3000 mode, a little higher speed than the plan ,as we also need to consider the maintenance time and holiday.
Type of Capsules and Fill Materials:
To produce different capsule size, we need to buy the additional change parts to meet the capsule size, such as the segments and capsule align parts, for instance, if your products are 0# and 00# capsules, then you need to buy two sets of change parts, also can buy other capsule size change parts for future use. EnsueThe fill materials, such as powders, granules, or pellets as the filling hopper and dosing system is also different. For some stick materials,we need to consider the special design damping pin, which can avoid the stuck of the powder in the dosing disc..
Budget and Investment Costs:
Evaluate your budget and the total landing cost, including the machine cost, freight cost, import tax, and packing cost. Maintenance, and changeover time. As time is also money, if you can save time for training your operator and maintenance, then you can make machine production more time.
Regulatory and Safety Compliance:
Ensure that the capsule-filling machine model you choose meets all relevant industry regulations and safety standards. Such as the stainless steel material and control function.
The room size and floor load bearing
Normally the height of the capsule filling machine is about 2m, so we need to ensure the ceiling height is enough, if we also want to put the powder vacuum loading machine on the top of capsule filling machine, 3m room height is best.When the machine install on the second floor then floor loading is also need to consider. So layout drawing is very important before we choose the models.
Installation Tips:
Choose position:
The location of installation should be free of vibration, level and sufficiently safe for floor load. Use rubber pads to decrease vibration. Adjust the machine bed to be level.
Environment
The machine should operate in a dust-free environment with the (21±3)℃ of ambient temperature and 40%-60% of relative humidity.
Power supply:
The site where the machine is installed should have supply facilities such as power and compressed air etc.
Maintenance Tips:
Cleaning
1.The parts of the machine that contact with powder directly should be cleaned regularly if machine operates normally for a long period of time. These include the capsule and powder hopper, dosing disc, seal ring, segment, pushing rods etc.. Especially when the machine is to stop operating for a long period of time and changes the product, it should be cleaned completely. The parts above machine table are not allowed to be cleaned with solvents including gasoline, kerosene, ether and acetone. Instead, they should be cleaned with fine cloth or absorbent cotton dipped in alcohol.
2. Stains on the driving devices at the lower part of the machine should be cleaned frequently to insure clear observation of operation. No oil is allowed to stay on the driving belt and the strap wheel.
3.The filter of the vacuum system should be opened for clean its jamming stains every now and then, or when the vacuum degree is unsufficient to open capsules.
Lubrication
- One layer of grease should be applied onto the work surface of the cam and roller once a week.
- Lubrication oil should be dropped onto the joint bearings and the sliding guides once a week.
- The ball bearings, needle bearing and linear bearings should be cleaned and lubricated by grease regularly or when necessary. Lubrication oil may be dropped onto the sealing bearings.
- The tightness of the driving chains should be checked once a week, with mechanic oil or lubrication greases being applied.
- The oil content of main driving decelerator and that of the feeder should be checked once a month and replenished if necessary. N46 GB443-89 mechanic lubrication oil should be replaced once half a year.
What are the common failures of automatic capsule filling machine
Incomplete capsule separation: If the capsules are not fully separated, it can lead to issues during filling or closing. This can be caused by worn or damaged parts in the separation system, incorrect capsule size settings, or a misaligned separation mechanism.
Inaccurate filling: Inconsistent or inaccurate filling can result from several factors, such as worn or damaged dosing components, incorrect dosing settings, or an uneven powder flow.
Capsule damage or deformation: Capsules may get damaged or deformed during the filling process if there is excessive pressure, misaligned parts, or if the capsules are not properly seated in the machine.
Capsule leakage: Poor sealing or closure of the capsules can lead to leakage. This can be caused by worn or damaged sealing components, incorrect sealing settings, or the presence of debris between the capsule body and cap.
Capsule blockages or jams: Capsules can get jammed or blocked in the machine if there is debris, dust, or misaligned parts. This can result in machine stoppages or damage to the capsules.
Inconsistent capsule discharge: If the discharge system is not functioning correctly, it can lead to capsules being ejected inconsistently or not at all. This can be caused by worn or damaged discharge components or incorrect discharge settings.
Machine stoppages or errors: Automatic capsule filling machines may experience stoppages or errors due to various reasons, such as sensor malfunctions, software issues, or mechanical failures.
The common auxiliary for capsule filling machine
Capsule polishing machine:
A capsule polishing machine is used to clean and polish the filled capsules to remove excess powder, reject the unopen capsule,half capsule and improve the overall appearance of the capsules. This equipment is the next step after the capsule-filling machine
Dust collector:
A dust collector removes dust and debris which is generated during the capsule filling process, it can ensure maintaining a clean working environment, reduce contamination risks, and improve product quality.
Powder loading machine
It can transfer the powder into capsule filling machine hopper directly,save time and labor cost
Capsule loading machine
It can transfer the capsule into capsule filling machine hopper directly,save time and labor cost
Metal detector:
A metal detector is working with the capsule filling machine to identify and remove any capsules that may contain metal contaminants. This helps ensure product safety and compliance with regulatory standards.
Weight checker:
A weight checker can be used to verify the weight of filled capsules, ensuring that each capsule contains the correct dosage of medication. This helps maintain product consistency and minimize the risk of medication errors.
Capsule inspection system:
Capsule inspection systems use cameras or sensors to check for defects in filled capsules, such as broken or misaligned capsules, incorrect sealing, or foreign particles. This helps ensure product quality and minimize the risk of product recalls.
Capsule printing
Capsule printing can be used to print or apply labels to filled capsules, providing important information such as product identification, dosage, and expiration dates.
Conveying and feeding systems:
Conveying and feeding systems transport capsules between different stages of the production process, such as from the capsule filling machine to the polishing machine or packaging equipment.
How to choose a capsule filling machine supplier
Reputation and Experience:
Choose a supplier with a good reputation and long experience in the industry. Fillitech has been working in the capsule filling machine export for more than 15 years, with a professional design engineer.
Quality Control System:
Quality control is a vital step during production and before delivery, Fillitech has accurate detection equipment from EU to ensure each part’s quality before assembly, and one team to test the equipment before packing, and one team to control the raw material and spare parts purchasing. All the process meets the ISO9001 and with CE certificate.
After-Sales Support and Service:
A reliable supplier should provide comprehensive after-sales support, including training, technical assistance, and maintenance services. Online service for 7*24hours at the same time
Customization and Adaptability:
If you have specific requirements or unique production needs, choose a supplier that can offer customization options or adapt their machines to meet your needs.
Warranty and Spare Parts Availability:
Fillitech can offer a two years warranty for our machines and provide two years’ spare parts. This will help minimize downtime once any issues or breakdowns.
Core parts quality
If the supplier has the matching ability to make the cors parts by themself, then it can save cost and easy to control the quality. Such as CNC machines
Landing cost
If the customer want to save time for logistics, then Fillitech can offer the landing cost, to provide machine to your factory directly, you do not need to arrange delivery and pick up at the seaport,even do the customs clearance,
What is the advantage of Fillitech‘s capsule-filling machine
High Capsule Filling Percentage
New design Vacuum sucker structure ,there are vacuum sucker that sucked the Lower modules holes tightly to avoid leakage air for more separate performance
Needle Type Blowing cleaning structure which for cleaning some sticky powder inside of the module holes . It is cleaned thoroughly for separate station much better
High powder filling accuracy within ±2％ at normal situations
Adopt double line dislocation arrangement for improving the filling weight accuracy
Adopt split type tamping holding device , It can adjust the filling weight separately to more accuracy weight variation
With double discharge chute structure ,it can observe front and back Row weight Filling and avoid powder pollution
No powder leakage
The special design of the copper ring , Greatly decreasing the leakage ,convince for cleaning
Fast change over
Adopt lower module location pin ,fast assembling different size mould
Low noise
Adopt Taiwan Xiangsheng Dividing box ,Sew motor , well quality , high performance .
Horizontal arrangement Main Motor will supply large torque,Low Noise ,smooth and steady
Famous brand of electric parts
Fillitech use Siemens PLC and Touch Screen System, PLC as the controlling center, and execution system parts are all international famous brand for stability and reliability
