Capsule filling machines are used to automate the process of filling the capsules with the contents that can be powder, liquid or pelletized medicine or supplement. They perform a function that would otherwise involve a lot of time and effort to carry out the activity of hand-filling capsules. This makes it easier for manufacturers to produce capsules in a relatively short time, without compromising the quality and quantity they wish to achieve.
In this ultimate guide, we’ll explore everything you need to know about capsule fillers including:In this ultimate guide, we’ll explore everything you need to know about capsule fillers including:
– A capsule filling machine is a device used to fill hard gelatin capsules with solid or semi-solid dose forms and seal them properly while a capsule filling process involves the use of this machine to fill the capsules with the correct dosage of the medicine and then seal them.
– The main categories of capsule fillers and their essential sub-assemblies are described here.
– Some of the specific aspects of key interest when choosing a machine are discussed below.
– Tamping Pins vs Dosator Nozzles: These are the Main Filling Technologies
– In this article, we will discuss the three major categories of fillers: manual, semi-automatic, and fully automatic fillers.
– Essentially, the process of using capsule fillers can be broken down into the following steps:
– Aberdeen’s research on best practices in cleaning and maintenance.
– Market Share and Trends of the Leading Capsule Filler Manufacturers and Models
With a grasp of capsule filling technology, one can make the right decision about what equipment to purchase based on production requirements and plant layout.
What Does Capsule Filling Machines Mean and How Does it Operate
Capsule filling machines are machines that are used to fill the empty two piece gelatin or vegetarian capsules at the same time and in a shorter span of time with powder medication, supplements or a combination of excipients. These act by grasping the capsule halves, positioning them, adjusting the opening of the capsule halves, sealing the capsule halves with a suitable substance and finally closing the capsule halves through mechanical operations.
In suspension powder or liquid formulation form, they are contained in a product hopper. The empty capsules are aligned depending on the direction by means of guides in addition to vacuum systems. The capsules are then opened mechanically to release the contents on to the plates with micro-wells.
Secondly, the opened capsule bodies are accurately filled with the pre-calculated volume/weight with the help of the filling pins or nozzles. The cap and the body essentially complete their formation and are ready to be deployed. Many systems are equipped with measuring weights and shun capsules that do not meet the prescribed standards.
The automatic capsule filling machines will fill over 100,000 capsules every hour and equally possess an accurate dosing mechanism. They provide greater rates of output than the slower methods of manual filling.
Main sections of capsule fillers and the classification of capsule filling machines.
Capsule filling machines have four major components:Capsule filling machines have four major components:
– An orientation system designed to properly place the empty capsules
– Orientation and a capsule feeding system that will ensure the movement of the oriented capsules.
– The dosing system which places respective products in capsules at a very fast rate
– The cap and body have a joined capsule closure mechanism
There are two main types of capsule filler:There are two main types of capsule filler:
Tamp filling machines: The direct contact should be done using tamping pins whereby the powder is compacted directly onto the opened capsules. This helps with determining the correct fill weights.
Dosator nozzle machines: Utilize vibrating nozzles over capsules to ensure the right quantities of medication dispenses through gravity/vacuum dosing. This reduces the chances of the product being contaminated by either the raw material or the environment, in case of direct contact.
In order to achieve the desired results, it is important to consider the following aspects of a machine.
Key capsule filler features and selection considerations include:Key capsule filler features and selection considerations include:
– Production output rate: extent of filled capsules per hour
– Capsule sizes handled: ranging from size 000 (largest) to size 5 (smallest)
– A higher degree of fill weight precision coupled with capsule variation.
– Compatibility to powders, liquids, pellets or pasty preparations
– Some of the other features that can be considered are the ease of size changeover and cleaning.
– Validation documentation availability
– Provided substantial and sturdy structures for rigorous manufacturing.
– This is in relation to the reputation of the vendor and the maintenance support services they provide.
Tamping Pins vs Dosator Nozzles: These are the main filling technologies:
The filling mechanism is essentially the process or device used to introduce powder or liquids into the opened capsules. The two main technologies are:The two main technologies are:
Tamper Filling Pins: Stainless steel pins arranged in blocks apply tamping force and directly transfer it to the powder for a proper fill to the capsule. Non-sticky and manageable powders that do not take much effort to maintain or to be held.
Dosator Nozzles: Applications: Powder coating or electrostatic or mechanical nozzles fill the capsules gravimetrically without a direct touch. Especially useful for products that cannot be contaminated by external factors.
The three classifications of Machines are: Manual type, Semi Automatic type and Fully Automatic type.
Based on automation levels, capsule fillers are available as:Based on automation levels, capsule fillers are available as:
Manual: An operator is responsible for all tasks such as feeding capsules, filling, closure, sealing etc.
Semi-automatic: Operator only loads hoppers/capsules, while dispense-pouches and bags are dispensed by the operator or the integrated counting/blending system. All other functions are handled by this device.
Fully Automatic: From refilling the hopper to the grinding of the coffee beans into the required capsule, everything is done on auto mode. The reject removal systems on the automated production line are used to check the fill weights.
Pharmaceutical-grade capsule fillers that are fully automatic are appropriate in high production volume with high level measurement of dosing.
Cycles Involves In Employing Capsule Fillers
The typical workflow to fill capsules using capsule filling machines is:The typical workflow to fill capsules using capsule filling machines is:
1. Check and confirm cleanliness of all parts needed and the setup of the machine with the proper capsule size.
2. Place the disinfected empty capsules in a hopper with their orientation positioned vertically
3. Amalgamate filling powder formulation into hoppers
4. This can also be done using the control settings such as the fill weights and speed.
5. Begin the implementation of machine checking with the goal of identifying any problems.
6. Keep weigh scale of sampled filled capsules accurate
7. Instruct the machine to operate and fill the capsules into the collection bins on its own.
8. Visually inspect the filled capsules systematically for any signs of defects
9. It should be equipped with the ability to halt the operation of the machine once a batch is prepared. Eject filled capsules and place them in appropriate containers or packs.
This chapter provides guidelines on cleaning and maintenance of facilities or working environment with particular emphasis on standards that have been proven to be effective.
To maximize uptime and reduce cross-contamination when filling different products:To maximize uptime and reduce cross-contamination when filling different products:
– It is also important to adhere to manufacture cleaning procedures to the letter
– As allowed by the machine design, take apart the various components in order to reach internal compartments
– Clean all contact parts and ensure that there are no traces of powder left in the areas.
– Cleaning with 70% IPA using wipes which do not shed fibre and debris
– Ensure that solvents residues do not remain in the jointed parts before reassembly
– This includes basic checks as routine maintenance such as changing gasket/seal.
It is important to have an understanding as well as strict compliance to cleaning validation procedures in pharmaceutical quality production.
The List of Leading Manufacturers and Different Models of Capsule Filler
– Bosch: GKF 7000S, GKF 800, CC-720
– Qualicaps: Q-Cap, Unicaps, DuoCap series.
– ACG Capsugel: Xcelodose 600S is an efficient and reliable solution for sample preparation of biological samples such as blood or tissue extracts, especially in cases when their concentration has to be determined.
– Torpac Inc: 20 station, 40 station manual fillers
– Cap Plus Technologies: Semi automated machines as well as fully automated machines
This contains a detail information that include everything to know about capsule fillers. It is, therefore, crucial to have the right machine that is properly matched to the volumes of formulation and the technical characteristics. If you have any questions, do not hesitate to reach out!
