Capsule Filling Machine Types: How Do They Work?

In the pharmaceutical industry, machines have a variety of uses. They perform a wide range of functions, depending on the setting. A capsule filling machine is one essential piece of machinery; It’s a big boon to the productivity of capsule filling.

Before delving into the mechanics of different filling machines, we’ll define the word “capsule filler.”

Capsule Filling Machine

A capsule filler is used to fill pharmaceutical capsules. Depending on the intended application, it is categorized as either domestic or commercial. Using privately, patients may easily use a personal capsule filler to dose the precise amount of medicine needed. Because of reliability and efficiency, pharmaceutical businesses rely on experienced capsule fillers for high-volume manufacturing.

 

capsule filling machine

Capsule Filling Machine Working Principle

Each machine has its operating system. The capsule filler runs in a step-by-step manner, as shown below.

  1. A capsule filling tray with transparent and colorless capsules in the proper positions.
  2. Separation of capsule tops from capsule bodies.
  3. Dosing the empty capsule with medicine.
  4. Mix and match the cap heads and bodies.
  5. Release filled capsules from the device.

All capsule filling machines, also known as encapsulators, operate similarly.

Capsule Filling Machine Types

The capsule filler comes in a range of sizes to accommodate the requirements of diverse industries. Capsule filling machines in the pharmaceutical industry are broken down into the following categories.

  1. Manual Capsule Filling Machine
  2. Semi-Automatic Capsule Filling Machine
  3. Fully Automatic Capsule Filling Machine

Here is a complete description of how the types of capsule filling machines work.

Manual Capsule Filling Machine

Manual capsule fillers are most often used at the individual level, but they are also in businesses where exact ingredient proportions are necessary.

The average manual capsule filler has a pressing capacity of 800 capsules.  The loading trays on these capsule filling machines may store up to 300 holes. The machine also has a tray for the powder it uses. The pin plate acts as a filter for the machine and a sealing plate for the capsules’ tops. The machine connects to a cam handle that operates a loading tray with an average of 300 holes. Because of the above high-quality qualities, a manual capsule filler is reliable for producing capsules to the user’s requirements.manual capsule filler

Manual Capsule Filling Machine Working Process

In a manual capsule filler, the cap and body are removed and placed in the filling tray while verifying the front knob. Filling and sealing empty capsules with filling ingredients. Then, pulling the locking lever forward. The long handle lifts caps off bodies. The capsule bodies are then leveled with the filling surfaces. 

Then, the filling product is measured and placed on the shelf. The product is then added to capsules. If necessary, machinery can compress powder products. After filling the capsules, move on to the next step, sealing. Next is pressing the capsules over the capsule body at the locking station to secure them. These capsules are on the loading tray, ready to leave the machine for packing.

 As a result, manual fillers are quite useful and may significantly boost output. The manual operations may be performed many times each hour, and production can be scaled up as needed.

Semi-Automatic Capsule Filling Machine

You could think of the semi-automated capsule filler as a mix between the fully automatic and the more labor-intensive manual machine. With semi-automatic equipment, people don’t have to do as much. The equipment is made to meet the high standards for cleanliness in the pharmaceutical industry. This piece of machinery is made well and is laid out in a way that makes sense, so it doesn’t need many repairs and lasts for a long time.

semi-automatic capsule filling machine

Small parts made of stainless steel and other non-corrosive proven materials decrease contamination risk and make capsule fillers appropriate for filling powders and granular substances in the pharmaceutical industry.

Fully Automatic Capsule Filling Machine

A fully automatic capsule filler is designed and engineered to fill capsules with medicinal powders without human participation automatically. Automatic fillers apply on a wide scale in pharmaceutical manufacturing. These capsule machines may include any powder or granules of microscopic particles in the body of the capsule. An automatic encapsulator is applicable as a whole system by adding other equipment, such as an online capsule polishing machine, dust extractor, damage capsule sorter, and empty capsule ejector.fully automatic capsule filling machine

A capsule filler is essential in the pharmaceutical industry to produce high-volume, sterile capsules. All of the foregoing, including the previous description, illustrates that capsule fillers are reliable pieces of technology for capsule production.

Automatic Capsule Filling Machine Working Process

Automatic capsule fillers can separate, fill, and lock capsules without human intervention. Thus, such devices may boost manufacturing efficiency and lower labor expenses. These machines run continuously or intermittently. Most pharmaceutical companies use intermittent motion automatic capsule fillers. The workflow consists of

  • Capsule Correction
  • Capsule Cap Removal
  • Reject Waste Capsule
  • Product Filling 
  • Capsule Assembly
  • Capsule Discharge
  • Capsule Tray Cleaning
1. Capsule Correction

Most capsules have fused caps and bodes. Thus, filling can begin once the attached capsules are separated. The capsule delivery plate features multiple inward-facing spherical holes for capsules to enter the machine. Channels have spring pieces at the bottom. 

As the capsule plate rotates up and down, capsules approach the inner channels and become trapped in the spring sections. When the delivery plate moves down, the spring components discharge the capsules methodically into the machine. 

At the front of the horizontal fork, capsules need more correction. The unique fork design concentrates on the capsule body’s smaller core diameter. The capsule will move with the body in front and the cap behind because of the difference in centers of gravity. 

The vertical fork adjusts the capsule direction. When the capsule body comes down, it enters the next section. This finishes capsule correction.

2. Capsule cap removal

Next, the capsule tray moves to the capsule separation area. The vacuum diver rises without gaps between the tray top and bottom section surface. The vacuum separates the capsule cap from the body. The capsule cap becomes stuck on the tray as the body descends.

The bottom and upper capsule tray portions are removed and moved after capsule cape separation.

3. Reject Waste Capsule

Some empty capsules are overlooked during separation for various reasons. With this, many pins are near the capsules. Pin rips capsule out of the mold, and blasts capsule Colling bags if capsule caps have not split from capsule bodies after separation. Split capsule bodies and caps go on to the next processing stage.

 4. Product Filling 

The conveyor belt transports the capsule body to the filling machine. There are four techniques to fill medication: intermittent dosing, tamping, vacuum, and dodging cylinder.

5. Capsule Assembly

The bottom and top capsule trays spin together at the capsule assembly, crossing their axes. As the capsule tray vibrates, the pin plate under it and the baffle plate above it move, locking the capsules’ tops and bottoms.

6. Capsule Discharge

The capsule discharge and rejection are identical. Locked capsules are pushed toward the capsule tray by the station pin. Then, sealed capsules are blown into the capsule exit by compressed air.

7. Capsule Tray Cleaning

After filling, the capsule tray returns to the capsule correction station. However, the capsule tray may include wasted capsules or powder. These need cleaning before restarting. Compressed air sweeps capsule tray powder and rejected capsules into the bottom dust collector.

Capsule filling machines work automatically. Because each step is fast and simultaneous, the system can fill 13,000–460,000 capsules each hour. Bulk capsule production is best with an automated filling machine.

Please visit our website and send us a direct message if you have questions about our capsule fillers. It is our pleasure to be of service to you!

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