Capsule Filling Machine

Capsule Filling Machine

Introduction:-
Capsule filling machine is the one which is used in the pharmaceutical
industries for filling the empty capsules. Capsule filler machine is also known as
encapsulation. Encapsulation is a mechanical device that is used at the industry
level for filling the powder formed active material of pharmaceutical industries
in the empty capsules.  Capsule filler machine is available in different types like
automatic, semi-automatic, and manual capsule filling machines. Capsule filler
functioning is to filling the powder and then locking the capsule.  A capsule
filler machine is always used for filling the bulks of capsules. The capsule filling
machine automatically ejects the capsule which is filled and locked in the
machines.

Types of Capsule Filling Machine

Automatic capsule filling machine
Semi automatic filling machine
Manual filling machine
Automatic Capsule fill machine:-
Automatic Capsule filling machine automatically fills the capsule by the
dry forms of powders. It is used in the industries for a large number of
production of the capsules. They are extremely durable in nature.

Including fully automatic capsule filling machine performs automatic

mode filling operations of capsules. Machine adopts intermittent motion
and multi-position tamping method to complete capsule orientation,
separation, filling, closing and ejection etc. With help of different size
parts, machine is suitable for size #00, #0, #1, #2, #3, #4 & #5 capsules.
The production speed can be controlled by means of a VFD (Variable
Frequency Drive). Machine is designed in accordance with cGMP
standards. All product contact parts are made of Stainless Steel 316 &
machine covered by Stainless Steel 304. Advantage of the machine is
advanced design, study structure, precise dosing, and safe and reliable,
high filling rate etc.

Being a capsule filling machine manufacturer we design with our

experience spanning close to two decades and the technology available
with us on secure filling and closing of capsules.  The design and

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construction of the machine encompasses all the cGMP aspects of

pharmaceutical sanitation. Interestingly, additional station of tablet
feeding or pellet filling in capsules can be offered on demand. We also
offer Capsule polishing, sorting, inspection, metal detection machines
which makes complete Automatic Capsule Filling Line.
Automatic Capsule Filling Machine, ACF – 40
Automatic Capsule Filling Machine, ACF – 70
Automatic Capsule Filling Machine, ACF – 150
 

Exclusive Features of Automatic Capsule Filling Machine

 Compact cGMP model.

 Programmable Logic Control (PLC) & display of all operations
 All the drive elements and the cabling at the bottom side separate
panel
 Crevice free smooth stainless steel pharmaceutical grades
 Automatic intermittent motion Driving Zone completely separate at
bottom and production zone at upper side
 Fill weight can be easily achieved by dosing disk thickness; the
weight variation can be maintained ± 3% by accurate dosing disc.
 Powder sensor maintains constant level of powder in the dosing
chamber and there will alarm in case of low level of powder in
dosing chamber.
 Easy to operation by central control touch screen and easy to
change dosing disc, tamping pins, capsule feeding & orientation
parts, capsule segments.
 Product contact parts are 316L SS and the other parts non-corrosive
material.
 Capsule can fill powder or pellets.
 Non-separated capsule will be ejected automatically.
 Option of attaching Capsule Polisher Line which includes capsule
polishing, sorting, metal detection machines.
 IQ/OQ documentation can be provided.
 Sampling system can be provided on demand.

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Semi-Automatic Capsule Fill Machine:-

The semi-automatic capsule fill name itself says that it is partially working
both automatic and manual both. Their equipment is very simple in
design and very easy to operate. It’s very hygiene in use.

Semi Automatic Capsule Filling Machine is designed for precision

manufacturing requirements of modern pharmaceutical procedures.
Capsule Filling Machine is suitable to fill size 00 to 5 capsules with
powder, granules or pellets. We are having three different models which
provide production output ranging from 25000 capsules per hour to
45000 capsules per hour.
Machine provides high Degree of automation with higher levels of filling
weight accuracy. Machine is made as per GMP standards having all
Stainless Steel covering.
Machine having wide usage in R&D laboratories, Research Institutions,
Herbal & Nutraceutical preparations, Unani & Ayurvedic medicines, Pilot
batch productions etc.

 Compact GMP model.

 Different model having output ranging from 25000 per hour to 45000 per
hour.
 On line capsule polishing & sorting can be attached to machine.
 Single operator can operate Capsule Filling, Polishing & Sorting
operations.
 Automatic empty capsule separation after Loading - No need to turn by
hand.
 Loader gets disengaged automatically after one complete rotation of
loading ring.
 PLC controlled digital display of all operations.
 Auger with four speeds to fill different type of powders & pellets.

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 Modified design of powder hopper reduces time for dismantling and

unloading of powder.
 Auto Powder hopper in-feed mechanism reduces weight variations &
improves productivity.
 Automatic declutching of loader when the loading rings are full minimizes
operator attention and ensures optimum production.
 Infinitely variable filling table speed ensures dosage accuracy.
 Automatically hopper in-feed mechanism eliminates weight variation,
reduces operator fatigue and enhances productivity.
 A choice of four augur speeds enables the machine to handle a wide
variety of powder from highly hygroscopic to the very free-flowing.
 Automatic Capsule Closing System ensures faster, safer closure and
ejection of filled capsules.
 No extra power consumption.
 No need to store filled capsule for polishing.

Technical Specification
Model ASCF-25 ASCF-35 ASCF-45

Production Up to 25000 Up to 35000 Up to 47000

Output Capsules/hour Capsules/hour Capsules/hour

M.O.C. of Magnesium Alloy Magnesium Alloy Magnesium Alloy

Loading Ring

Number of Single Single Double

Ring

Number of Size 00: 360 Size 00: 480 Size 00: 480
Size 0: 480 Size 0: 600 Size 0: 600

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Model ASCF-25 ASCF-35 ASCF-45

Holes/Ring Size 1,2: 540 Size 1,2,3,4,5: 720 Size 1,2,3,4,5: 720
Size 3,4&5: 600

Product Stainless Steel 316 Stainless Steel 316 Stainless Steel 316
Contact Parts

Loader drive: 0.25 H.P., 380/440 0.25 H.P., 380/440 0.5 H.P., 380/440
Volts, 3 Phase, 50 Volts, 3 Phase, 50 Volts, 3 Phase, 50
Hertz Hertz Hertz

Auger drive: 1.5 H.P., 380/440 1.5 H.P., 380/440 1.5 H.P., 380/440
Volts, 3 Phase, 50 Volts, 3 Phase, 50 Volts, 3 Phase, 50
Hertz Hertz Hertz

Filling Table 0.5 H.P., 380/440 0.5 H.P., 380/440 0.5 H.P., 380/440
drive: Volts, 3 Phase, 50 Volts, 3 Phase, 50 Volts, 3 Phase, 50
Hertz Hertz Hertz

Vacuum 3 H.P., Oil Type 3 H.P., Oil Type 6 H.P. Oil Type (3
Pump: H. P. x 2 nos.)

Vacuum: 500 mm (20) of Hg at 1000 Liters/min (30CFM)

Compressed 200 Liters/min (8 CFM) at 100 PSI

air:

Manual Capsule Fill Machine:

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Manual Capsule machines are mostly used for the small-scale Pharma
industries as they produce less amount of capsules so it can be done
manually. It requires no power and it is operated by hand.manual capsule
filling machine is considered an ideal capsule filler with manual operation
for small to medium batch size requirement in industries like
pharmaceutical, nutraceutical, Ayurvedic, Herbal and dietary supplement.

The hand capsule filler model has the competence to fill and close hard
gelatin capsules with powder & pellets. Our company has partnered with
several pharmaceutical manufacturers and have taken proper measures
to ensure that the capsules are precisely filled in order to achieve new
levels of success with capsule-filling. The machine can open, fill and
capsules at a rate of 300 per cycle, handling tablets of different size that
ranges from 00 to 5 that requires changing of parts. Basic model of the
filling machine comes with a single size change part set. For further
requirement of other size, request can be made for the change parts.

Manual capsule filling machine is a flexible bench top pharmaceutical

equipment that boasts of having the capacity to produce 8000 capsules
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per hour. The machine is hence deemed felicitous for clinical research
organizations and special laboratories as they require cost effective
manual capsule filler for smaller runs. It can be completely dismantled
and hence is quite easy to maintain and clean. The manual capsule filling
machine is designed to handle a wide variety of capsules. At this
competitive price, 300 holes manual capsule filling machine is the best
machine that can be offered. All the contact parts of the machine is
designed from stainless steel 304 that provides immense strength to the
structure. The non contact parts of the manual capsule filler, on the other
hand, are manufactured using mild steel and hard chrome plated for an
aesthetic look. A 300 Holes Manual Capsule Filler is potent enough to
handle difficult powder and products.

The non contact parts of the manual capsule filler, on the other hand, are
manufactured using mild steel and hard chrome plated for an aesthetic
look. A 300 Holes Manual Capsule Filler is potent enough to handle
difficult powder and products. Manually operated machines possess a
bed of around 200 to 300 holes, a loading tray with 200-300 holes and a
powder tray. Other important segments of this machine include a pin
plate, a sealing plate with a rubber cap, and a lever. A handle with a
loading tray encircled with 250 holes on an average is capable of
producing around 6250 capsules per hour. Small scale manufacturers and
hospitals utilize this type of encapsulators for extempore preparations. In
the case of manually operated machines, the two parts of the capsules
are detached and are inserted into the loading tray. The empty capsules
are poured with the filling materials and then sealed off.
Capsule filler is a type of machine used to fill empty capsules with
pharmaceutical ingredients. These capsules fillers are divided into 2
categories depending upon their uses i.e., personal capsule filling
machine & professional capsule filling machine. Personal capsule filling
machines is for small scale production and utilization. These personal
capsule filler machines allow people to fill their capsules with the
necessary medication. On the other hand, professional capsule fillers are
used in pharmaceutical industries at large scale production with high
efficiency.
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Working Principle of Automatic Capsule Filling Machine

After starting up the machine, the empty capsules in hopper will be fed
into the slot of magazine vertically. With each stroke of machine, the
fingers of magazine will release one row of capsules into rectifier
raceway. The horizontal fingers rectify the direction of capsules and
vertical fingers push the capsules into hole of segment with all caps on
the up position. The capsules in the holes are sent to each working
station along with the intermittent rotation of the turn table.

 At the 1st & 2nd station, the vacuum system separates the capsules

in position.
 At 3rd station, the lower segment with capsule body extends out
ready for the filling.
 4th station uses to fill pellets.
 At the 5th station, the tamping pins push the pressed powder slug
into capsule body.
 6th station to re-joint cap & body segments.
 At 7th station non-separated capsule get eject.
 At 8th station vertical pins pushing body of capsule into the cap for
re-join and close the filled capsules.
 The 9th station is to eject the finished capsules.
 At the 10th station the holes of segments are cleaned by vacuum
cleaner and compressed air. Then the segments are ready for next
cycle of operation.

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The powder from a SS hopper entered to a chamber of dosing plate &

temping pins for dosing, the height of the powder is controlled at
chamber by a material level sensor. Tamping device is work by a 6
working station of intermittent mechanism, there are 6 groups of
standard holes on dosing disc. The powder filled in holes was made of a
slug that reaches the weight of dose after 5 tamped. At the 6th working
station the slug pushed by tamping pin into capsule body. Adjusting the
height of tamping pin holder can be changed the filling weight of powder.

WORKING PRINCIPLE OF A CAPSULE FILLING MACHINE

Every machine has its own working method. The capsule filling machine
works in a step-by-step process that is as mentioned below.

1. The positioning of colourless & translucent capsules in the capsule

filling tray.
2. Division of capsule caps from their bodies.
3. Filling up the capsule body with pharmaceutical ingredients
4. Rearrange the caps and bodies
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5. Expulsion of filled capsules from the machine

This working method is common in all different types of capsule filler

machines that are also known as encapsulators.

KEY FEATURES OF MANUAL CAPSULE FILLING MACHINE

 Around 8000 capsules/hour can be manufactured with the help

of manual capsule filling machine.
 The machine can handle various complex powders
 Different type of capsules can be handled with this machine
 The movement and bench top mounting is easier in the manual
capsule filling machine
 The machine has an added advantage of being 100% disassembled
 The machine can be completely washed as per the GMP rules

MODELS AVAILABLE IN MANUAL CAPSULE FILLER:

 GMP Model: Complete designed from Stainless Steel 304

 Standard Model: All contact parts designed from Stainless Steel 304
& Non – Contact parts designed from Mild Steel with Hard Chrome
plating

STANDARD OPERATING PROCEDURE OF MANUAL CAPSULE FILLING

MACHINE (SOP):-

Placing Capsules in the Manual Capsule Filler

 Put empty capsules in the loading tray and place it onto the
machine

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 Pull locking handle forward, push down the long lever to lift the
caps of the capsule bodies
 Put the tray with caps aside
 Push the locking handle back and capsule bodies will come to the
filling surface

Filling Powder in the Capsules

 Put powder tray to avoid spilling of the powder

 Pour the right quantity of powder and spread it. Bring down the
tamper and lock it
 Turn the handle given above to compress the powder
 Bring up the tamper. Pour & spread the extra powder.

Covering the Capsules

 Put the tray with caps to filler and bring down the locking plate.
 Lock the plate and turn the front knob to the right
 Push the long lever down to push capsule bodies into caps
 Open the locking plate lock, lift the locking plate and turn the front
knob to the left
 Pull down the long lever and lift the tray with filled capsules
 Turn the tray to get filled capsules out of the tray

BENEFITS OF MANUAL CAPSULE FILLER

 Simplistic design
 Easy operation
 Precise filling
 Reduction in powder wastage
 Strong and highly durable
 Cost-effective

Advantages of Capsule filling machine

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They are the lower power consumption machine.

It is a scalable and high-speed filling machine.
Capsule fill machines are fully GMP base compliances.
Some Capsule filling machines are only used in Aseptic fill to weight.
Capsule fill machine helps to prevent Pharma industries from the loss of
the powder material to almost 90%.
It is a highly flexible, accurate, and precise machine for the Pharma
industries.
 
Hence, choosing the correct capsule fill machine is a very difficult task so
we should keep in mind various things:  brand, manufacturer, Production
capacity, quality assurance and many more
a. Low production efficiency
Manual capsule filling machines can only fill 10 to 800 capsules per cycle,
and produce up to 600 to 4000 capsules per hour. Though this is much
more efficient than simply filling capsules by hand, its production capacity
is overshadowed by semi-automatic and automatic ones. After all, they
boast a much more complex mechanism and can manufacture 10k to
450k capsules per hour.

b. Low Filling Accuracy

Another big drawback is that without the help of a computer program, it's
difficult to pin down the exact amount of powder for each capsule. So
manual capsule filler is hardly possible to achieve the micro-dosing of
capsules.

c. High Labour cost

Human labour is indispensable when filling the capsules. Besides, as it is a
separate machine that does not support production integration, you need
to manually move finished products to capsule polishers. All the work is
laborious compared with automatic production lines.

Technical Specification of Automatic Capsule Filling Machine

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Mac ACF– ACF ACF– ACF

hine 25 – 40 70 – 90
Mo
del

Prod Up Up Up Up
ucti to to to to
on 25,0 40,0 70,0 90,0
Out 00 00 00 00
put caps caps caps caps
/ ules ules ules ules
hou
r

Cap 00/0 00/0 00/0 00/0

sule /1/2/ /1/2/ /1/2/ /1/2/
Com 3/4/ 3/4/ 3/4/ 3/4/
bina 5 5 5 5
tion
s

Con SS SS SS SS
tact 316 316 316 316
part
s

Non SS SS SS SS
– 304 304 304 304
Con
tact
part
s

Pow 4 K. 4 K. 6 K. 6 K.
er W. (6 W. (6 W. (8 W. (8
Sup H. P.) H. P.) H. P.) H. P.)
ply

Pow 415 415 415 415

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er Volts Volts Volts Volts

Volt ,3 ,3 ,3 ,3
age Phas Phas Phas Phas
e, 50 e, 50 e, 50 e, 50
Hertz Hertz Hertz Hertz

Air 4 4 4 4
Req CFM CFM CFM CFM
uire
d

Mac 975 975 1300 1275

hine mm mm mm mm
Dim 875 875 1200 1200
ensi mm mm mm mm
ons 1955 1955 2300 2200
App mm mm mm mm
rox.
Leng
th
Wid
th
Heig
ht

Net 850 850 1400 1600

Wei kg s. kg s. kg s. kg s.
ght
App
rox.
* Power voltage can be adjusted as per customer’s domestic power
voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.

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