Hard Capsule Filling Machine

What is Capsule Production Equipment?

Capsule production equipment mainly consists of capsule filling machine, capsule polishing machine, manual capsule filler, liquid hard capsule filler, softgel making machine, encapsulation machine, and capsule inspection machine.

We provide high-quality capsule filling machines at a competitive price. Whether you need to fill powders, granules, pellets, or liquids into capsules, our capsule machines can provide you with an ideal solution. All capsule filling machinery is fully cGMP and FDA certified and manufactured to the highest standard to meet a wide range of filling needs.

Highlight of Hard Capsule Filling Machine

• Large number of capsules can be filled per hour depending on machine design and model.
• Different models are available for various clients based on their manufacturing needs.
• Equipment designed to handle a wide variety of capsules.
• Easy mounting and user friendly operation and parts replacement hence very low down times.
• Easy assembly and disassembly for cleaning and maintenance purposes.
• The equipment is fully washable as per the good manufacturing practices (GMP) rules.
• Newer improved designs have negligible final product rejections and ensure better return on investment.
• Contact parts made of stainless steel and non corrosive materials to eliminate contamination and easy cleaning.
• Long life and trouble free operations.
• Table and partial filling attachments can be offered to fit the specific needs of the business and specific formulations.
• High quality loading plates.

Machine Specifications and Technical Parameters

NJP-3800Series Closed Full-Automatic Capsule Filling Machine Outfit

Hard Capsule Filling Machine Working Principle

Every capsule filler has its unique working principle. The step-by-step working process of the capsule filling machine is as follows:

• Positioning of translucent and colorless capsules in the capsule filling tray.
• Removing the capsule caps from the body.
• Filling the capsule body with prescribed pharmaceutical ingredients.
• Rearranging the capsule caps onto the capsule body.
• Expulsion of the filled capsules from the machine.

All capsule-filling machines or encapsulates have the same working principle.

Different Types of Hard Capsule Filling Machine

Manual Hard Capsule Filling Machine

The manual capsule filling machine is highly suitable for small to medium size production. This filling machine for capsules mostly finds application in industries like-pharmacies, pharmaceutical, nutraceutical, Ayurvedic, Herbal and dietary supplement industry. It is a hand-operated machine and can fill as well as close hard gelatin capsules with powder & pellets. This capsule line machine has the ability to open, fill and close capsules at a rate of 300 per cycle. The manual capsule filling machine has an advantage of handling a plethora of capsules. Hence, its versatility provides an edge over other machines for industrial applications. The manual capsule filling machine is provided with a capsule loader to save time and labour. It aids in yielding higher production rate with improved accuracy. The capsule loader automatically loads the empty capsule in the loading plate for manually operated capsule filling machine and is an ideal choice for medium and large scale pharmaceutical applications.

Semi-Automatic Hard Capsule Filling Machine

The semi-automatic capsule filling machine is specially designed for modern pharmaceutical procedures for the precise manufacturing requirements. This machine gives increased accuracy level of filling weight apart from having a higher degree of automation. The semi-automatic capsule filling machine is adept at filling capsules of all sizes with powder, granules, or pellets. In this machine, the capsules are first loaded into the hopper. The powders, on the other hand, are loaded on a separate hopper. This is a corkscrew driven hopper that provides an assurance of constant fill through each capsule. The machine is provided with a vacuum in order to separate the capsules. By pulling the loading rings, the bottom section is released which is then placed into the filling part of the machine. The corkscrew then pushes the powdered material into the capsules evenly.

Automatic Hard Capsule Filling Machine

An automatic capsule filling machine is a high speed capsule filling machine that has the capacity of filling up 90000 capsules per hour with different variants of powder formulation. It is known for precise filling operation of the entire range of hard gelatin capsules with powder, pellets, and granules. The machine comes with a tamping pin technology that aids in slug formation that is later inserted into the hard gelatin capsule for enhanced accuracy. Automatic capsule filling machine is equipped with a programmable logic controller for machine control.

Advantages of Hard Capsule Filling Machine

Capsules Can Be Filled With Various Dosage Forms

Capsules can be filled with research or clinical samples in various dosage forms, including powders, two-layer granules, oil or paste liquids, and tablets. The powder filling method can be switched between die compression and mechanical vibration.

Easy Conversion

Both the cap disc and body disc are one-piece discs with excellent separation accuracy, which facilitates re-assembly after conversion, disassembly, and cleaning.

Highly Accurate Filling

The most suitable filling method can be selected to suit the characteristics of the powder, enabling highly accurate filling. In particular, the vibrator system with intermittent operation further extends the vibration time when the machine is stopped, and provides superior filling accuracy not seen in conventional vibratory filling machines.

Key Parts of a Hard Capsule Filling Machine

Capsule Hopper

The capsule hopper is primarily the " feeding chute " of the capsule filling machine. This hopper typically uses food-grade stainless steel for durability and hygiene. Depending on the capacity of the machine, the capsule hopper can come in a variety of shapes, such as cylindrical, conical or cubic. Beyond storing the capsules, the hopper also feeds the capsules into the filling machine using a controlled vibration system. This helps to stabilize the flow of capsules while maintaining precise positioning and separation for correct filling.

Capsule Feeding System

Imagine thousands of capsules piled messily in a hopper. How can you pick out only one capsule that is oriented exactly the same way for filling? A capsule feeding system can help. It precisely separates each capsule and keeps it upright and ready for filling. It may seem like a small job, but one irregular capsule can cause a lot of problems for the entire production line.

Powder Hopper

Next is the powder hopper. You can think of it as the machine's storeroom. It stores the powders, pellets, or other things that will go into the capsules. But it's more than just a simple container! The hopper utilizes a clever mechanism, such as gravity or a rotating screw, to keep this material flowing to the next station. This ensures that you always have enough material on hand for precise filling.

Powder Dosing & Filling System

We all know that the powder dosing filling system is the core of the capsule filling machine. So what is its main job? That is to measure and fill the exact amount of powder for each capsule. But there is no magic one-size-fits-all solution here. Different powders behave differently, so you need to use different dosing mechanisms to ensure maximum accuracy. Here are two of the most common methods:

• Dosator– This method uses a piston or screw to draw and measure a specific amount of powder from a hopper. The measured dose is then ejected into the capsule. Dosator is highly accurate and suitable for a wider range of powder types, including poorly flowing powders.
• Dosing Disc– This method uses a rotating disk with multiple cavities. As the disk rotates, the tamping pin pushes the powder from the hopper into the cavities. Once filled, the disk rotates further and the tamping pin compacts the powder. Finally, the compressed powder is ejected into the capsule. The dosing disc may not be suitable for all types of powders, especially less fluid powders. Also, it may not be as accurate as the dosator.

Lubrication System

In a capsule filling machine, the powder dosing system and capsule feeding unit take center stage, but there is another key part that works tirelessly behind the scenes, that is the lubrication system. As the machine operates, various parts move and rub against each other. Without proper lubrication, friction can cause these parts to wear out early, which may lead to potential machine breakdown. The lubrication system oils these parts and reduces friction. This will in turn extend the life of the machine.

Vacuum System

One of the main functions of a vacuum system is capsule separation. Capsules are usually stored in a large hopper and tend to get mixed up. Vacuum systems utilize low pressure to gently separate individual capsules from the bulk supply. This allows the capsules to enter the filling station precisely one by one. In addition, the vacuum unit cleans the capsule zone after each filling cycle. This quick cleaning with no manual intervention eliminates any leftover powder or debris and ensures a clean and consistent filling process for the next capsule.

Motor

In a capsule filling machine, the motor is like the engine of a car. It is the main power source that keeps everything running. It takes electrical energy and converts it into the power needed to run the various parts of the machine. Think of it this way, the parts of a capsule filling machine are like individual tools. The motor provides energy for the operation of these tools and further ensures smooth filling of the capsules.

Safety Door

The safety door is mainly designed to protect the operator. When your capsule filler is running, the parts inside will move very fast. If the operator accidentally puts his hand into the machine at this time, he could be seriously injured. This is why we need a safety gate in the capsule filler. It serves as a physical barrier to prevent the operator from putting himself in danger.

Control System

The control system of a capsule filling machine usually has two parts, the PLC and the HMI. PLC (Programmable Logic Controller) is a specialized computer with a set of pre-programmed instructions. These instructions tell each part of the capsule filler what to do and when to do it. For example, it tells the dosing system how much powder to deliver, when the feeding unit releases the capsules, and when the safety gate locks.

Common Applications of Hard Capsule Filling Machine

For powder filling

One of the most common applications of an automatic capsule filling machine is powder filling. As you know powders are solid and dry particles which are produced by crushing solid substances. This process is fairly simple and doesn't involve complex procedures. Powder capsule fillers are quite simple in terms of structural design when it comes to the hoppers and dosing system.

Filling pellets

Pellet filling is another important application, an automatic capsule filling machine is used for. There are a number of automatic encapsulating machines that can perform this task. You must know that the speed used for filling pellets is lower than the one used for powder filling. You may have to make some modifications in the equipment to perform this task though. For instance you may have to make changes in the dosing system to make it well-suited for performing this task.

Granule filling

In the pharmaceutical world, powder flow and content uniformity are quite important, but there are times when it becomes quite difficult to achieve it. This is where granule automatic filling machines come into picture. The coating on the granules is of utmost importance and hence it must not be damaged. The coating is of gastric resistant polymers and the machine should not damage it.

Liquid filling

As you know there are times when liquids are required to be filled and hence you need a capsule filling machine that can fill liquids in capsules. A wide range of viscosity spectrum is needed to be taken into consideration while performing this task. Majority of liquid filling automatic machines use a servo controlled liquid pump for enhanced performance.

Filling capsules with different substances

There are times when you need a capsule filling machine that is capable of filling a combination of products such as liquids and semi solid substances. Automatic capsule filling machines are quite versatile and perform variegated tasks without compromising on performance.

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