GKF 2500 | GKF 2500 ASB | GKF 2500 ASB IPK | GKF 2500 ASB 100 % | GKF 3000

GKF 2500
Capsule Filling Machine
Packaging Technology
2 | GKF 2500 – Capsule Filling Machine
Modularity, Flexibility and
Economical Operation in Capsule Filling
Whichever products you would like to fill – powders, pellets, tablets,
liquids, micro-dosing or combinations, the GKF 2500 offers the correct
solution in the high speed production range
The GKF 2500 is a versatile and flexible
machine. This provides a high versatility of fill
options with varying product tapes. Even
complex products with varying fill parameters
can easily be processed. Thanks to the modular
design of this capsule filler, the machine can
be changed-over in a minimal amount of time.
Ergonomical and Secure Handling
With a focus on ergonomics and cleanability, our
engineers developed a machine that minimizes
change-over and cleaning times and therefore
maximizes productivity. The cGMP-compliant
production cabin ensures easy accessibility and
user-friendly operation and cleaning. Likewise,
machine sub-assemblies are quickly and easily
exchangeable, for example, during format
change-overs.
The GKF 2500 ASB IPK with in-process control
provides you with weight control via statistical
evaluation, with documentation of the sample,
day, and batch data.
Machine control via the touch-screen HMI is
especially user-friendly. The control of the
machine and measurement data collection are
handled via an industrial PC. All production data
is also saved and managed on the industrial PC.
The windows-based software complies with the
data security guidelines of 21 CFR part 11.
Quick and Easy Operation
The machine table-top is seamlessly machined
as one piece. This allows for large-radius con-
tours without undercuts, according to proper
GMP design. Furthermore, only FDA-approved
 GKF 2500 – Capsule Filling Machine | 3

The design of this capsule filler provides for quick and complete
cleaning, as well as efficient change-overs. Thereby, the machine fulfills
all modern cGMP requirements. The PC-based control system also
allows for automatic data-logging of all production processes.
Therefore, the GKF 2500 sets new standards in pharmaceutical security.

The GKF 2500 ASB 100% is equipped with an
integrated checkweigher. Every capsule produced
on the capsule is individually and precisely
weighed. Only capsules with a weight within
the pre-set tolerances are accepted. Over- and
underweight capsules are rejected.
The GKF 3000 is based on the successful
GKF 2500 and sets a new benchmark in the
pharmaceutical industry with its output of
175,000 capsules per hour. This machine
is reliable, low-maintenance, and provides
production security.

materials are used. The maintenance-free main
drive allows for quiet operation of the machine,
reduces wear, and extends the machine lifetime.
▶ Highly accurate dosing
▶ Simple operation
▶ cGMP-compliant design
▶ Flexible dosing possibilities
▶ Low-maintenance operation
▶ Data security
▶ Reliability
▶ Optimal accessibility
As the fastest tamping pin principle machine on
the market, the GKF 3000 offers precise dosing
with minimal product loss. Powder or pellet
products are gently filled and even products
with varying fill parameters can be optimally
filled via height-adjustable dosing disks. A spe-
cial seal separates the production and drive
cabin, thereby protecting the product from
foreign contaminants.
4 | GKF 2500 – Capsule Filling Machine

Functional Description
and Dosing Options

Functional Description

2
1 3

12 4

11 5

10 6

9 7
8

1 Capsule orientation and separation 8 Open for optional pellet or tablet station 1
2 Capsule orientation and separation 9 Capsule closing with capsule body scanner (ASB function)
3 Capsule cap scanner (ASB function) 10 Capsule ejection
4 Open for an optional pellet or tablet station  Individual capsule ejection with ASB function

5 Dosing station for powder/pellets via 11 Capsule ejection

fixed or height-adjustable dosing disk, Individual capsule ejection with ASB function
iquid filling station or micro-dosing station 12 Segment cleaning
6 Open for optional pellet or tablet station Segment cleaning with compressed air (ASB function)

7 Faulty-capsule rejection

No ASB function available on the GKF 3000 1 Optional pellet station on the GKF 3000
 GKF 2500 – Capsule Filling Machine | 5

Powder/Pellets
Dosing station with
patented slidegate
technology for filling
of powder or pellets.

Micro-dosing 1 Pellets
Highly precise The pellet station
dosing of small offers gentle filling
powder volumes and is ideally
(e.g. Inhalation suited for use in
products). combination filling.

Tablets 1/Micro-tablets 1
A defined number of tablets
can be filled precisely via
the tablet station

Liquids 1
The servo-controlled
liquid pump offers the
ideal filling technology
for a broad viscosity
spectrum.

Combinations Custom Solutions

Numerous product The GKF 2500-series provides
combination fills the opportunity to customize
are possible on the filling solutions, thanks to its
GKF 2500-series open platform.
thanks to its modular
design.

1 Not on the GKF 3000

6 | GKF 2500 – Capsule Filling Machine
Optimal Productivity
via Quality Control
Reliable Operation via Automatic
Trouble-Shooting
The automatic trouble-shooting feature auto-
mates your production and reduces your down-
time. The calibration strip in the empty capsule
sorting magazine ensures that deformed or
damaged empty capsules are removed even
before the filling station.
The mechanical capsule cap scanner determines
if there are blockages in the empty capsule
ASB function
infeed. A repeated missing capsule in a
particular segment bore is recognized by the
consecutive fault function. Deformed capsules
in the capsule magazine are blown out via
individual compressed air lines and routed to
a separate deformed capsule container.
The capsule body scanner recognizes incomplete
capsules during capsule closing. Therefore,
incomplete capsule portions do not make it into
the good capsule production container.
The capsules that have been determined to be
faulty are individually rejected at the 18 capsule
ejection flaps. The segment cleaning station with
compressed air nozzles loosens sticky products
and capsule fragments from the segment bores
and reliably vacuums them away. This station
ensures the cleaning of all the segments for the
next filling cycle.
 GKF 2500 – Capsule Filling Machine | 7

The GKF 2500-series guarantees optimal productivity and pharmaceutical security

in capsule filling with it’s automatic trouble-shooting features (ASB), in the GKF
2500 ASB, GKF 2500 ASB IPK or GKF 2500 ASB 100% versions.

GKF 2500 ASB 100% with
Online Weight Control
Beyond the advantages of ASB, the integrated
weighing system offers you a secure and
documented production process.
fill weight. If a capsule is outside the tolerance
range, it is automatically rejected. The incident
will then be documented in the production
report.

The highly accurate weight-control feature ▶ Out-of-tolerance capsules are

automatically controls fill weights with its
pneumatic adjustment of the tamping pin
pressure. Thereby, it is ensured that the
desired fill weight is maintained within the
specified tolerance range for the entire
production process.
The analysis software calculates an average
fill weight from the checkweigher results
and compares this average to the theoretical
automatically rejected
▶ Reduction of machine downtimes
▶ Lights Out Operation
▶ The capsule filling machine can be
operated with or without the 100%
checkweigher
▶ The checkweigher can be operated
with or without the capsule filler
8 | GKF 2500 – Capsule Filling Machine

No Risk – Weighing Technology

of the Highest Quality
GKF 2500 ASB IPK with In-Process Control
Filled capsule samples are individually removed In-process
from the filling process and weighed at pre- control
(IPK)
defined intervals. The sampling process can be
completely defined by the user. The analysis
software calculates an average fill weight from
the checkweigher results and compares this
average to the theoretical fill weight. If the
average weight of several samples exceeds
the tolerance limit, the tamping pin pressure
is automatically adjusted by the pneumatic
tamping pin adjustment function. The incident
will then be documented in the production
report.

After the sample capsules are weighed they

are collected in a separate container. The
individual weights are indexed according to
their position in the segment. The scale will
tare itself after every capsule it weighs.

KKE 2500 –
weighing cells
 GKF 2500 – Capsule Filling Machine | 9

GKF 2500 ASB 100% with KKE 2500 Functional Description 100% Check Weighing

Accurate weighing method

The Bosch patented “hanging weigh cell” 1 2
principle safely weighs all capsules while
avoiding dust or residue build up within the
weighing cell. In addition the weigh cell
design eliminates electrical interferences 3
4
such as electrostatic fields.
5
Dependable production documentation
Data for the entire production run is stored
and digitally evaluated by the user friendly
operating system. All of the data available 8 7 6
on the system can be saved on the integrated 1 Capsule Hopper

DVD Burner or transferred to an external 2 Insertion Pusher

system via the USB port. 3 Magazine
4 Calibration bar

Size changeover in < 1 min 9 5 Size Plate

The ergonomic design, which sucessfully 6 Separating Flaps

meets cGMP requirements permits a size 7 Transport Finger

changeover in less than one minute. All 10 8 Weighing Cell

change parts can be quickly disassembled 9 Transport Wheel

without tools, allowing rapid cleaning with 10 Discharge Flap

no residues.

Easy, fast cleaning

Due to the hermetic separation of the
production and drive section (balcony
design) there is no contamination of
the product and the machine is easy
to clean.

Standard automatic trouble shooting

(ASB)
The ASB function automatically detects
and ejects deformed capsules, helping
to eliminate unnecessary downtime and
increase productivity.
10 | GKF 2500 – Capsule Filling Machine

Technical Data

Machine cycles Infeeds Formats

Max. 140 cycles/min.
 Powder infeed – Triclamp
 Capsule format set for all standard

DN 150, DIN 32676 capsule sizes, 00 to 5, D B
Electrical connection Pellet/Tablet infeed – Triclamp

380–480 V, 50/60 Hz 3 pH/PE
 DN 100, DIN 32676 Options
Special voltages
 Empty capsule infeed – Triclamp
 Height-adjustable dosing disk

16 kVA total
 DN 100, DIN 32676
Filling options:
Maximum amperage Standard equipment Powder filling station

16A
 Base machine with integrated
 Pellet filling station

electrical cabinet and built-in HMI Liquid filling station²

Vacuum pump electrical connection Machine control: industrial-PC
 Tablet filling station²

1,85 kW, 50 Hz, 2,2 kW, 60 Hz
 Empty capsule hopper with
 Micro dosing station²

minimum and maximum level
Vacuum requirement control sensors Accessories
50
 m3/h at -250 mbar Adjustment of the dosing disk
 V
acuum pump for capsule

height separation
Utility Connections Capsule closing station with
 Dust collector

Compressed air supply Ø 13 mm
 concave closing pins Automatic powder feeding

V
acuum pump connection
 Cleaning station with compressed
 Empty capsule feeder

Ø 30 mm air nozzles and vacuum suction Capsule polisher

Dust collector connection

 Metal detector

2 x Ø 70 mm Distribution system

V
acuum pump electrical

connection 1 optional on GKF 2500
Jogging cable connection
 and GKF 3000
D
ust collector electrical
 2 Not on the GKF 3000
connection
Main electrical connection


GKF 2500 2500 ASB 2500 ASB IPK 2500 ASB 100% 3000
Output (max. capsules/h)
150,000 150,000 150,000 150,000 175,000
Segment bores 18 18 18 18 21
Compressed air consumption
(m³/h at 5 bar) 2 2 4 20 2
Dust-collector electrical connection 200 | 220 | 380 | 400 V
50 Hz, 2 x 4 kW
220 | 380 | 400 | 460 | 480 V
60 Hz, 2 x 4,6 kW
Dust-collector air flow volume 20 m³/h, open suction
Weight (kg) ca. 1,700 ca. 2,000 ca. 2,200 ca. 3,300 ca. 1,700
 GKF 2500 – Capsule Filling Machine | 11

GKF 2500 / GKF 2500 ASB / GKF 3000

2762
2762
2762

24662466
2466
20272027
20722072
2027
2072

2220 1389
2220
2220 1389
1389

2762
GKF 2500 ASB IPK
2762
2762

24662466
2466
20272027
20722072
2027
2072

2320 1389
2320
2320 1389
1389

2762
GKF 2500 ASB 100%
2762
2762
24662466
23432343

2466
20272027
20722072
2343

2027
2072

1389
3061
1389
1389
3061
3061
Robert Bosch
Packaging Technology GmbH
Product Division Pharma Solid

Stuttgarter Straße 130

71332 Waiblingen
Germany
Phone +49 711 811-0
www.boschpackaging.com
packaging-ph@bosch.com

For more information, please visit:

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