The Ultimate Buyer's Guide for Purchasing Automatic Capsule Filling Machine

1.What Is An Automatic Capsule Machine?

Allpack Automatic Capsule Machine

Link to Jiangyin Chenyuan Machinery

An automatic capsule machine is a highly specialized type of machine that is used to fill and encapsulate different types of particles, powders into capsules in an efficient manner. These machines fill various types of substances in capsules and then are consumed for various reasons. Complete processes in an automatic capsule machine are carried out in an aligned sequence that makes the production precise and uniform.

2.What Are The Industrial Applications Of An Automatic Capsule Machine?

Automatic capsule machines are currently present in all types of small and large scale industries. These industries have optimal usage of automatic capsule machine to enhance their productivity. Some of the industries using automatic capsule machines are

Pharmaceutical Industry

Pharma Capsules - Picture Courtesy: Pharma Franchise Company

Pharmaceutical industry is the largest consumer of an automatic capsule machine as capsules are one of the orally consumed medications globally. These capsules of different sizes and shapes are filled and sealed using automatic capsule machines in an efficient manner. Machines ensure that the ratio of dosage inserted is according to the standards and is approved by different clinical trials.

Food Industry

Nutrient Supplements

Food industry is also a consumer of an automatic capsule machine as it also produces products that are in the form of capsule. Ingredients like chocolates, jellies, vitamins and supplements are filled in these capsules that make consumption easier and also attract adults towards them.

Cosmetics Industry

Cosmetics Hyaluronic Acid Capsules - Picture Courtesy: Republic Cosmetics

Some of the vitamins and protein health care products that are used as cosmetic products are also present in the form of capsule. These capsules are filled and sealed using an automatic capsule machine. It makes the product look presentable and attracts number of customers towards it.

Agricultural Industry

Nutrient Capsules For Agriculture

Capsules having organic fertilizers and nutrients that are useful for agricultural land are also manufactured using an automatic capsule machine. These capsules generally contain products that are essential for agricultural land and to improve its internal strength.

3.What Are The Advantages Of An Automatic Capsule Machine?

Some of the advantages of an automatic capsule machine are

Productivity

Capsules Productivity

The designing of an automatic capsule machine is done in a way that it helps the manufacturer to produce large volume of capsule in limited time. The procedure is done to keep the system remain efficient in each of the capsule and to keep complete similarity in them.

Efficiency

Efficient Manufacturing Of Capsules

Efficiency is another benefit that can be gained using an automatic capsule machine. It is taken in the context of chemical composition that each of the capsules has equal dosage formulation to work effectively. The mechanism ensures consistent flow to keep the medication dosage filled in an efficient manner using an automatic capsule machine.

Formulation Flexibility

Flexible Formulation Of Capsules

One of the leading advantages of an automatic capsule machine is that it allows wide range of capsule filling in a single machine. Whether it is powder, pellets or granules that has to be filled in capsules, a single automatic capsule machine can accommodate each of the formulation in it in an efficient and precise manner.

Consistency

Elongated Consistent Capsules Making

Quality is a factor that helps to check the consistency of an automatic capsule machine. It provides flexibility in producing capsule by using highly accurate sensors and actuators. These components help to fill accurate amount of formulation in capsules and maintain consistency in them.

4.What Is The Steps Involved In Working Of An Automatic Capsule Machine?

Automatic Capsule Filling - Picture Courtesy: grupobsg

The working of an automatic capsule machine follows several series of steps. These are internally coordinated with each other to maintain the system run efficiently .These steps are

In the first step, both the empty capsules and powder in inserted into their respective hoppers present at the top of machine. Both the object s is delivered in an automatic sequence to the filling stations where they are blocked by highly advanced mechanism.

In the block-shelf, the capsule direction is using guide slots that adjust the capsules both upward and downward for proper filling. Both of portions of capsules are separately adjusted into the lower and upper molds and stick by vacuum suck so that chances of falling can be eliminated.

In the third step the filling of capsules placed in die mold is carried out. The material released from the powder hopper enters into these capsules cap by filling nozzles in an accurate amount.

After the completion of filling process, both the cases of capsules are locked together by a dose plate so that no spillage can occur.

As the capsules are ready, they are discharged from the system through a proper ejection system that continuously pushes them out from the mold surface. The mold gets cleaned after each capsule formation by a vacuum chamber to maintain consistency in the system.

5.What Are The Main Components Of An Automatic Capsule Machine?

Components In An Automatic Capsule Machine

The main components of an automatic capsule machine are

Hoppers

Both of the powder and capsule hoppers are present in an automatic capsule machine that is used for holder of filling material and capsules respectively. A capsule hopper is mostly with a vibration support that ensures segregation of capsules and to allow their free flow.

Operation Panel

An operation panel of an automatic capsule machine contains all the options involved in product processing. The productivity is controlled by increasing and decreasing of speed controller present on this operation panel. Other options like start on and off button, emergency buttons and others are also present in this panel.

Vibration Device

As capsules are attached altogether in a hopper it is always necessary to segregate them and separate each of them to maintain efficiency and consistency in system.It minimizes the risk of error and keeps capsule flowing individually to fill and get sealed.

Vacuum Chamber

Vacuum chamber in an automatic capsule machine has dual functions to perform. Initially it helps in capsule segregation and then also supports in cleaning the machines to maintain hygienic environment. These are mostly present at the bottom side of an automatic capsule machine where it can perform both of the tasks efficiently.

Filling Nozzle

The capsule material is dispensed into the capsules through a highly systematic filling nozzle that helps in its release and also in an accurate manner. The specific limit of material is dispensed so that consistency is maintained in each of the capsule.

Ejection System

Once the capsules are filled and sealed properly, they are taken out of the system through this ejection system. An ejection system works an offloading channel from where all the capsules are collected and moved forward for their packaging and transportation.

6.How Does An Automatic Capsule Machine Improve The Efficiency Of A Process As Compared To Other Types Of Capsule Machines?

Automatic Capsule Filling Machine

An automatic capsule machine has an ability to perform at a high speed and makes rapid production in a very short interval of time. It processes thousands of capsules filling and sealing procedures in a single day with its highly automatic system and maintains the quality in each single capsule.

Further improving the efficiency of any system is also due to its compatibility with different sizes of capsules. Each capsule is filled with an accurate amount of dosage as defined standard and filling duration allowed to it. The machine remains user friendly and gives an access to reach out all its working parameters that can help in improving the systems efficiency.

7.How Different Sizes Of Capsules Are Produced In A Single Automatic Capsule Machine?

Capsule SizeChart- Picture Courtesy: LFA Capsule Fillers

Flexibility with different sizes of capsules and their filling is one of the most important benefits an automatic capsule machine can offer. It can easily accommodate various sizes of capsules in it as it holds an adjustable filling station and nozzle that varies according to the size of capsule. These can easily be changed and modified according to their sizes in just a fraction of time.

The parts of an automatic capsule machine are interchangeable that can be replaced easily by the operator. This makes efficient filling and sealing of different types of capsules in a single machine to make the system economical.

8.What Are The Major Differences Between A Manual Capsule Machine And An Automatic Capsule Machine?

Some of the differences between a manual capsule machine and an automatic capsule machine are

Productivity

Improved Productivity

A manual capsule machine is mostly used in small scale or cottage industry where the productivity is in low volume. It has a capacity of producing few hundreds of capsules in a hundred or depends upon the working efficiency of the operator.

Mostly high and medium scale industries use automatic capsule machines to make their run in a faster way. Thousands of capsules of different sizes and shapes can easily be produced in a single automatic capsule machine.

Structure

A manual capsule machine has a simple structure and handed completely by manual operations. A hopper is present in it with manual placing of capsules.

Whereas in an automatic capsule machine has a highly systematic processes for filling, sealing and feeding of capsules. It has a complex structure and sometimes include conveying system too that helps in movement of capsules within the system.

Application

Both of the machines are applied in pharmaceutical, food, cosmetics, agricultural and chemical industries depending upon their requirements and productivity.

Precision And Accuracy

Capsule Filling Machine Tool

Manual capsule machines are low in precision and accuracy due to manual involvement and slow process.The machines precision and accuracy solely depends on the performance of operator.

On the other hand an automatic capsule machine has a high precision and accuracy levels to maintain consistency in the system. Each of the capsule formed show similarity in structure and composition both.

9.What Are The Process Line MachinesAssociated With An Automatic Capsule Machine?

Auxiliary machine are associate with an automatic capsule machines to enhance its productivity and to produce highly quality products that can attract more and more customers towards it. Some of them are

Capsule Counting Machine

Capsule Counting Machine

To accurately count the number of capsules present in a batch, capsule counting machine is one of the advanced modes to do so. The process of a capsule counting machine saves a lot of time and does it with greater efficiency as compare to manual counting.

Blister Packaging Machine

Blister Packing Machine

For packaging of completely processed capsules, blister packaging machines are used in many of the industries that make their packaging easier. Blister packaging machines work in a highly efficient manner and packages capsule according to the shape of packaging and the number defined to them.

Conclusion

For high productivity of capsules in an efficient and precise manner, an automatic capsule machine is the most reliable thing to select. It can be used for filling and sealing of capsules that are different in size and shape. But you need complete machine related information to select the right type of automatic capsule machine for your setup. For this All pack is always here to provide you complete machine related information and help you in buying the best product. For any query contact our customer representatives that are available 24/7 for your guidance.

Are you looking forward to purchasing a capsule filling machine? It is one of the biggest investments that any pharmaceutical company can do. However, getting a pharmaceutical machine is not the easiest job you can do. Once you are on the market, you will find different models and types. You should carefully analyze them and pick the right one that suits your production needs. Moreover, it must match your budget as well. Here are 8 factors to keep in mind when looking for that perfect capsule machine.

1. Capsule Type and Size

The very first thing you should consider is the type of capsule you are going to fill up. Along with that, you should also determine the capsule size. You can use a capsule filling machine to fill up:

• Hard gelatin capsules
• Softgel capsules
• Vegetarian capsules

Out of these, gelatin capsules are made out of animal byproducts. They contain a higher volume of gelatin, water and preservatives. You can get them in standard sizes 5 is usually the smallest and 000 is the largest.

Softgels come with a smooth exterior. If you are going to fill up liquids, you need to use them. On the other hand, vegetarian capsules use a cellulose instead of gelatin.

You need to take a look at dosage and density of the contents when selecting a type of capsule as well. Larger volumes would require bigger capsule sizes. Based on the selected capsule, you can pick a machine to fill up.

2. Production Output Requirements

Manual capsule filling machines have an output of around 100 capsules per minute. On the other hand, semi-automatic capsule filling machines can offer up to 100,000 capsules per hour. A semi-automatic machine is mostly okay for your needs. But if you have a higher production output requirement, you may proceed with a fully automatic machine.

However, you need to keep in mind that semi-automatic capsule production machines come at a higher price tag. This is where you need to compare your return on investment.

Automatic capsule fillers are ideal for pharmaceutical producers filling thousands to millions of capsules daily. Lower capacity semi-automatic or manual fillers may suit nutraceutical companies with smaller runs.

3. Level of Automation

Capsule filling machines come in manual, semi-automatic or fully automatic versions. Manual capsule fillers involve entirely hand-operated filling. This is where the operator separates capsules by hand. Then you will need to fill powders/liquids manually and close capsules by hand. They allow small batch production with maximum flexibility. That’s because you will have to spend a lot of time filling up the capsules through this method.

Semi-automatic machines automate some functions in the capsule machine. They include dosing and tamping but require manual capsule loading/unloading. Such semi-automatic machines offer faster outputs for small to medium batches. Fully automatic capsule fillers integrate all functions. You can use them to automate:

• Orienting of the capsules
• Capsule filling
• Closing and ejecting of capsules

As a result, you can proceed with producing high volumes with speed and precision. Automatic units are ideal for large pharmaceutical and neutraceutical production runs.

4. Adjustability and Customization

It is better if you can spend to buy an adjustable capsule filling machine. Then you can accommodate different capsule sizes. In other words, you will be able to have better production flexibility.

It is a good idea to pick a machine that allows easy size changeovers. Moreover, you can also pick a machine that offers additional dosing stations. Such customized features can make your life easy as you produce capsules.

5. Powder/Liquid Handling Capabilities

You need to keep the type of capsule filler in mind when selecting a filling machine. It can be:

• Powder
• Liquid
• Combination of both

To fill up a capsule with powder, it requires a special system. They will enable filling up the powder precisely into the capsule. Moreover, these systems make sure that the dry powder remains consistent in the capsules.

On the other hand, liquid capsule fillers come with a pump and nozzle system. They inject the liquids directly into capsules. These machines keep track of accurate filling volumes at all times.

Some advanced capsule fillers handle both powder and liquid filling. Alternatively, you can purchase separate powder and liquid capsule filling machines.

6. Cleaning and Maintenance Needs

After getting the capsule filling machine, you will have to clean it regularly. Some of the machines require manual cleaning. But it is better if you can invest in a machine with automatic cleaning. They have the Clean In Place (CIP) technology as well. This allows you to clean the machine without disassembling it.

7. Electrical Requirements

Based on the region, you will either have 110V or 240V at your production plant. You need to pick a capsule filling machine that you can operate as per the electrical input you can provide.

If you operate in an area with unstable electricity, always go for a system with a UPS. Then you will be able to overcome blackouts and ensure consistent production.

8. Investment Budget

The type of capsule filler suitable for you ultimately depends on your production scale and budget. Manual and semi-automatic powder or liquid fillers start around $5,000 to $10,000. Fully automatic pharmaceutical-grade capsule fillers range from $50,000 up to $500,000+ for high-end integrated machines with custom features. Define your budget constraints during the selection process to narrow viable options. Weigh required automation levels against capabilities and cost.

Getting a capsule filling machine is an investment. This is why you need to evaluate ROI when making a decision.

Frequently Asked Questions

Now you have a basic overall idea about buying a capsule filling machine. However, you may still have some unanswered questions on your mind. Follow this section and we will share answers to those questions as well.

What is the cost of a capsule filling machine?

It depends. If you buy a manual capsule filling machine, you don’t have to spend a lot. However, semi-automatic and fully automatic capsule filling machines are quite expensive.

For example, a manual capsule filling machine can cost you around $10,000. On the other hand, fully automatic pharmaceutical grade machines can cost more than $500,000. You should be ready to invest around $50,000 to $100,000 to purchase a decent capsule filling machine. Define your budget beforehand and then look around for the options. It will make life easy to pick the right product.

Should I buy a used capsule filling machine?

If you can’t afford the cost of a new capsule filling machine, going for a used one may seem the best option. However, there are benefits and drawbacks to evaluating when making this decision. For example, you will need to see the condition of the capsule filling machine you get.

Some of the pharmaceutical companies mandate new equipment only. If you are working with such a company, you should be willing to invest in a new machine. But if such a requirement is not there, you may start off your business with a used capsule filing machine. It will help your business save some capital. You can upgrade to a newer and better one as your business proceeds.

What production rates do different capsule filling machines offer?

Production rate is one of the key factors that determine your choice of getting a capsule filling machine. Some of the prominent production rates you can expect include:

• Manual: <1,000 capsules/hour
• Semi-automatic: 1,000 - 40,000 capsules/hour
• Automatic: 40,000 - 100,000+ capsules per hour

It is completely up to you to evaluate these production rates and pick the right filling machine. Then you can use it to run your business without any issues.

How quick are size changeovers on capsule machines?

The changeover time of a basic capsule filling machine is around 15 minutes. However, semi-automatic capsule machines can offer up to two hours. A good thing about semi-automatic capsule filling machines is that they offer tool-free change parts. As a result, you can experience faster changeovers between the runs.

What tolerances to capsule fill weights can I expect?

At the time of buying a capsule filling machine, you need to be aware of filling weights as well. The average weight tolerances of a capsule filling machine include:

• ±5-10mg for powder filling
• ±50mg for liquid filling

Tighter ±3mg tolerances are achievable on high precision machines.

How much space do capsule filling machines require?

To accommodate a capsule filling machine, you will need to allocate a space of at least 3x4 feet. However, make sure to provide another 2 feet of perimeter to enable operator access and airflow. Some of the new capsule filling machines offer a compact and modular design. You can easily accommodate such a machine. However, larger automatic machines would require up to 400 square feet.

What safety mechanisms should I follow when operating a capsule filling machine?

A capsule filling machine usually comes with a variety of safety features. They include:

• Finger guards
• Emergency stops
• Light curtains
• Protective covers
• Overload detection and many more

Along with the machine, you will receive safety instructions to follow. Make sure to follow them at the time of operating the machine. Then you can ensure safety and operate the machine.

How should I clean the capsule filling machine?

Basic capsule filling machines require manual cleaning. However, advanced machines offer programmable in-place cleaning systems with advanced fillers. You need to look at your preferences and pick the right machine.