Capsule Filling Machine

SaintyCo capsule filling machines are CE and cGMP certified. The encapsulating machines can fill different capsule sizes – #00 to #4, with up to 450,000 pcs/hour depending on the machine. SaintyCo’s top selling products include: fully automatic capsule filling machine, semi-automatic capsule filling machine and manual capsule filling machine.

Capsule Filling Machine: The Ultimate FAQ Guide

If you want to skyrocket your capsule filling business, then this guide is for you.

It covers everything you need to know about capsule filler equipment, from working principle, classification, machine qualifications, benefits, etc.

You will learn everything you need to know in this guide – let’s get started:

1. What is a Capsule?

A capsuleis an easy to swallow container that comes in different shapes for administering different types of drugs and nutrients.

Capsules

Capsules

You will use a capsule to administer medicine which you may not be able to compact into tablets due to:

• The taste may be too horrible for you to swallow

• The medicine or nutrients maybe in a liquid or pellet state

2. What are the main Ingredients of Making a Capsule?

You will use different types of ingredients in making a capsule because the capsules are available in different varieties.

The variation is important especially in terms of the dietary needs of the patient.

Here are the ingredients that you will use in making gelatin capsules.

• Gelatin

You will use gelatin as the main ingredient for making the outer shell of the capsule.

Gelatin is an animal product that comes from collagen which you can extract from animal skin and bones.

• Pullulan or Hypromellose

Since gelatin is an animal product, you will substitute it with another ingredient to make a suitable capsule for vegetarians.

Pullulan or hypromellose comes as the best alternative for gelatin.

Pullulan is a type of polysaccharide that is soluble in water while hypromellose is a product of raw cellulose.

You can use tapioca instead of gelatin to make vegetarian capsules for vegans and people who follow a strict religious diet.

• Potato Starch Matrix

Apart from the above ingredients, you can also use potato starch matrix to make capsules for vegans.

It is a transparent, smooth, and neutral tasting plant product that resembles gelatin.

It is also friendly to the stomach thus making it a proper alternative for vegan capsules.

• Plasticizers

You will also include plasticizerssuch as glycerin, and sorbitol which decreases the capsule hardness.

• Preservatives

You will add preservatives to the ingredients to increase the shelf life of the capsules.

• Coloring Agents

You will include color to the ingredients to increase the attractiveness of the capsule.

Apart from that, opaque colors will protect the active inner fill materials from harmful effect of incident light and UV rays.

It increases the stability of the active inner fill materials as it decreases the formation of free radicals.
Additionally, opaque colors decrease the possibility of the active oil ingredients from being rancid.

In that case, you will add opacifiers to the ingredients to make the color opaque.

• Lubricants

You will need lubricants to make the active ingredients soft and easy to swallow.

• Solvents

The main solvent that you will use in making capsules is water since it is universal and fits many applications.

• Disintegrants

You will add disintegrants to the ingredients to promote proper breakup of the ingredients within the capsule.

• Surface Treatment

You will add surface treatments to capsules to protect it from external factors that might damage the capsules.

• Inner Fill Materials

You can use three main types of inner fill materials to make a complete capsule.

The three types of inner fill materials include:

i. Neat substances such as oily liquids

ii. Solution fills including soy beans oil, Myglyol 812, and polyethylene glycols.

iii. Suspension fills which will actively disperse in different carriers.

3. How many Types of Capsules are there?

There are two main types of capsules that you can choose from including:

• Hard Gelatin Capsules

Hard Gelatin Capsules

Hard gelatin capsule

You will manufacture hard gelatin capsules using the fully automatic capsule filling machine.

The process of making the outer shell and filling occur at different stages.

It can easily adapt to all capsule filling applications because they are easier to fill with different inner fill materials.

Most of the hard gelatin or two piece capsules are available in two parts which include the cap body and the cap of the capsule.

• Soft Gelatin Capsules

Soft gelatin capsules

Soft gelatin capsules

You will manufacture soft gelatin capsules from a single material.

Implying that manufacturing and filling of soft gelatin capsules takes place at the same time.

It is the most suitable capsule for non-aqueous solutions and will melt as soon as it reaches the stomach.

4. What is Capsule Filler Machine

SaintyCo capsule filler machines

SaintyCo capsule filler machine

A capsule filler equipment is a device that you can use to fill empty capsules with a variety of substances.

Some of the substances that you can fill into empty capsules include medicine or nutrients.

Capsule filling machines are available for you to choose from for private use at home.

Apart from that, you can purchase a capsule filling machine for industrial use for filling empty capsules on large scale.

5. What are the Uses of a Capsule Filling Machine?

You can use different types of capsule filling machines for different applications especially for:

• Pharmaceutical companies

• Local Drug Stores

• Users of nutritional supplements and natural herbs.

You can use the machine to fill different types of inner fill materials into different types of capsules.

You can purpose to use the capsule filling machine for both domestic as well as commercial applications.

Domestically, you can use the capsule filling machine to pack your own capsules.

Commercially, you will use the capsule filling machine to produce different types of capsules on a large scale.

6. What are the Benefits of a Capsule Filling Machine?

When using a capsule filling machine, you will realize a lot of benefits.

Here are the main advantages of using the capsule filling machine.

• Cost Effective

Using a capsule filling machine will save you a lot of money that you could use in other tedious capsule filling practices.

In case you are using it domestically, you will save money from the highly priced capsules you buy over the counter.

Commercially, you will save money by eliminating high cost of labor if you are using a fully automatic capsule filling machine.

• Easy to Use and Maintain

The process of using a capsule filling machine is simple and direct as you will only have to follow the instructions.

It become easier especially when you are using a fully automatic capsule filling machine as it performs most of the functions.

It comes complete with a PLC control panel for easy configuration, control and monitoring of the machine.

The cost of maintenance is also low as most machines have self-diagnostic systems that will alert you for proper maintenance.

• Make Unique Capsules

You can easily make unique capsule with different ingredients and shapes that will fit your requirements.

You have the liberty of choosing the type of inner fill materials as well as shapes of the capsules.

You will also have proper knowledge of the ingredients that you are consuming since you are in control of the systems.

• Enables Mass Production

With all the factors of production at hand, you can easily produce capsules on a large scale.

Using a fully automatic capsule filling machine, you will save time and money in producing capsule on a large scale.

This is because you will eliminate the need of employing many workers and the machine fills numerous capsules at a time.

• Upgradable Machinery

You can easily upgrade the capsule filling machine depending on the kind of technology that is available.

Most fully automatic capsule filling machines have the capability of upgrading to boost the speed and efficiency of production.

• Economical Mode of Production

Using a capsule filling machine will eliminate wastage of materials as it is precise and accurate in the filling process.

Other benefits of the capsule filling machine include:

i. It employs different capping technologies that allow production of different formulations.

ii. It produces different capsule forms that have health and nutritional benefits to the user.

iii. It enhances precision, accuracy and consistency with all the capsules it produces

iv. It will also guarantee proper uniformity of the mixture of ingredients.

7. Does Capsule Filling Machines have any Disadvantages?

Automatic capsule filler machine

Automatic capsule filler machine

Yes, just like any other machine capsule filling machines also have its disadvantages.

Here are some of the cons that you might experience while using a capsule filling machine.

• High Cost of Investment

You will have to dig deeper into your pockets especially when you are purchasing a fully automatic capsule filling machine.

It is expensive to purchase and install a fully automatic capsule filling machine.

You need to prepare a lot of warehouse space where you will install the machine thus increasing the cost.

Apart from that, you might need to train your workers or higher professionals to help in the machine operations.

• Limited Portability

This factor depends on the type of capsule filler equipment you are using.

The bigger the machine and the higher the level of automation, the less portable it will be.

Implying that manual capsule filling machines are more portable in comparison to fully automatic capsule filling machines.

Fully automatic capsule filling machines are bigger and heavier thus limiting the movement from one place to another.

8. What are the Considerations in the Capsule Filling Process?

In the capsule filling process, you have to take particular factors under consideration.

Here are the main factors that you need to look at in the capsule filling process.

i. Type of Capsule

The type of capsule that you intend to fill will determine the type of machine that you are using.

You can use a fully automatic capsule filler equipment to fill different types of empty capsules including hard or soft gelatin capsules.

ii. Type of Inner Fill Materials

You will also choose the type of capsule filling machine depending on the type of inner fill material.

For instance, you cannot use a semi-automatic or manual capsule filling machine to fill liquids.

iii. Type of Machine

Your choice of machine for the capsule filling process will determine a number of factors.

It will determine the speed, efficiency, types of capsule and inner fill materials as well as scale of production.

9. How does a Fully Automatic Capsule Filler Machine Compare to a Manual Capsule Filling Machine?

Fully automatic capsule filling machine

Fully automatic capsule filling machine

Manual capsule filling machine

 Manual capsule filling machine

Manual capsule filling machines are devices that you can use to fill empty hard gelatin capsules with medicine and nutrients.

On the other hand, an automatic capsule filling machines can either fill empty hard gelatin capsules or Softgel capsules.

Using both machines, it is easier to fill any size of empty capsules with a range of nutrients or medicine depending on you specific requirements.

You will need to hire human labor to help in performing most of the activities when using a manual capsule filling machine.

A manual capsule filling machine is slower than an automatic capsule filling machine thus a terrible option for large scale production.

Automatic capsule filling machines are faster and requires minimal human assistance making it efficient for

large scale filling of capsules.

10. How does a Manual Capsule Filling Machine Compare to a Semi-Automatic Capsule Filling Machine?

Semi automatica capsule filling machine

Semi-automatic capsule filling machine

A semi-automatic capsule filling machine depends on the automatic aspect of the machine as well as human assistance.

Unlike the semi-automatic capsule filler machine, you will need human labor to assist you with the manual capsule filling machine.

In terms of speed, a semi-automatic capsule filling machine works faster than a manual capsule filling machine.

Despite the high speed, semi-automatic capsule filling machine are more efficient and accurate in comparison to manual capsule filling machines.

You can use the semi-automatic capsule filling machine for medium scale production as it slower for large scale production.

11. How does a Fully Automatic Capsule Filler Machine and Semi-Automatic Capsule Filling Machine Compare?

Fully automatic capsule filling machines are faster and depend purely on the automatic aspect to perform most functions.

You will, however, need the assistance of a few professional technicians to assist in some of the activities.

On the other hand, a semi-automatic capsule filler equipment depends partly on the automatic aspect and require human labor.

You will need more human labor to help in operating a semi-automatic capsule filling machine thus affecting the speed.

Fully automatic capsule filling machines are faster, more efficient and accurate in filling capsules on large scale.

You can only use a semi-automatic capsule filling machine to fill hard gelatin capsules.

A fully automatic capsule filling machine is efficient for filling hard gelatin capsules as well as Softgel capsules.

12. Where can you Use a Capsule Filling Machine?

You can use a capsule filling machine in different applications both domestically and commercially.

Here are the main applications where you can use a capsule filling machine.

1) Pharmaceutical Applications

In this case, you can use the capsule filling machine in filling different types of medical products into empty capsules.

Apart from that, you will fill nutrients and other body supplements in the right quantities using capsule filling machines.

2) Nutraceutical Applications

In the nutrition industry, you will fill different nutrients into empty capsules using a capsule filling machine.

It accurately and efficiently fills the nutrients into empty capsules thus avoiding wastage of ingredients.

3) Food Industry

You will need to administer particular food supplements using capsules.

You will, therefore, fill the food supplements into capsules using different types of capsule filling machines.

4) Domestic Applications

You can use the capsule filling machine in filling your own capsules within the comfort of your home.

It is a cheaper mode of filling capsules and you will have proper knowledge of the inner fill materials you are consuming.

13. What is a Manual Capsule Filling Machine?

A manual capsule filling machine is a device that you can use to manually fill empty hard gelatin capsules.

You can use a manual capsule filling machine to fill nutrients and medicine on a small scale like inside your home.

14. What are the main parts of a Manual Capsule Filling Machine?

Parts of manual capsule filling machine

Parts of manual capsule filling machine

A manual capsule filling machine has numerous parts that enhance their function and efficiency.

Here are the main parts of a manual capsule filling machine.

• Loading Tray

You will place all the empty capsule in the loading tray before you proceed with the manual filling process.

It is available in various capacities depending on the scale of your production.

• Capsule Holes

You will move the empty capsules from the loading tray and into capsule holes.

In the capsule holes, the capsule will stay in an upright position awaiting the filling process.

• Locking Lever

The locking lever will lock the body of the empty capsules in place as you remove the caps of the empty capsules.

• Handle

With the handle, you can control the locking lever as you separate the caps of the empty capsules from the body.

• Caps Tray

You will use a caps tray as the holding plate for the caps after separating them from the body of the empty capsules.

• Powder Tray

In case you are use powder as the filling material, you will place it on a powder tray.

A powder tray holds the filling material in preparation of the filling process.

• Filler

You will use the filler to guide the filling material straight into the body of the empty capsule thus limiting wastage.

• Guiding Nozzle

With the help of the guiding nozzle you will ensure that you accurately fill the empty capsules with the right quantity.

• Tamper

The tamper has the powder compressor which will assist you in compressing the powder perfectly into the capsules.

• Powder Compressor

As part of the tamper, the powder compressor will stuff the powder to fit perfectly into the empty capsules.

• Turning Knobs

You will use the turning knob to adjust direction of movement and the tightness of the moving parts of the machine.

15. Does a Manual Capsule Filling have Benefits?

Using a manual capsule filling machine comes with numerous benefits.

Here are the main benefits that you will experience while using the manual capsule filling machine.

• You will spend less in the original cost of purchase and installation in comparison to other types of capsule filling machines.
• Due to its small size you can easily move it from place to place and place it on a work bench as you operate.
• Using the manual capsule filling machine is the most economical way of small-scale production of hard gelatin capsules.
• You will not need to train professionals to assist in operating a manual capsule filling machine due to ease of operation.
• The cost and process of cleaning and maintenance is low as it is easy to dismantle and assemble the machine.

16. What are the Drawbacks of Using a Manual Capsule Filling Machine?

The manual capsule filling machine also presents a few drawbacks when you are using it.

Here are some of the disadvantages of using a manual capsule filling machine.

• You can not use it on large scale production since it is slow and can only fill a few capsules at a time.
• You will also have a hard time in determining the quantity of filling material that you will be filling.
• You will need the services of other machines such as capsule polisher in the production process thus increasing the cost.
• Apart from that, you also need the services of extra personnel in the filling process thus increasing cost of production.
• Human labor is prone to exhaustion thus limiting the active time for filling the empty capsules manually.
• You cannot integrate a manual capsule filling machine into a production line thus reducing its large-scale production efficiency.

17. How does a Manual Capsule Filling Machine Work?

10 Working of manual capsule filling machine10 Working of manual capsule filling machine

 Working of manual capsule filling machine

You will fill empty gelatin capsules using a manual capsule filling machine by going through the following steps.

Step One: Preparation Stage

First, you need to prepare the manual capsule filling machine by cleaning it and greasing the moving parts.

Apart from that, you will prepare the empty capsules as well as the ingredients to fill into a hard gelatin capsule.

After that, you will place the empty capsule on the loading tray and the filling material on the powder tray.

Step Two: Loading the Manual Capsule Filling Machine

At this point, you will carefully fill the capsule holes with the right number of capsules with the caps facing up.

Ensure that you lock the capsules using the locking lever so that they can hold in place when removing the caps.

You can achieve this by pulling the lock lever of the capsule filling machine forward.

The manual capsule filling machine will not only lock the body and place it in an upright position.

It will also lock the caps thus making it easy to separate them from the body of the empty capsule.

You will push the long handle down and the head of the manual capsule filling machine will remove the caps.

Carefully transfer the caps onto the caps tray.

Step Three: Filling the Capsules

At this point, you will transfer the filling powder from the filling tray and into the fillers.

Carefully position the filler above the empty capsules with the nozzles facing the empty capsules.

Release the filling powder and the nozzles will guide it straight into the empty capsules.

After that, you will lower the tamper into the capsules and compress the powder to create more room.

The powder compressor will compress it allowing for more room to fill the capsules appropriately.

Repeat the above process using the filler and the tamper until the capsule is full to capacity.

Step Four: Covering the Body of the Capsule

Return the tray holding the caps and position it well above the full body of the capsules.

Carefully lower it down by turning the left knob to the right as it lowers the locking plate.

Engage the locks and hold the tamper in position as you push down the long handle.

The manual capsule filling machine will raise the body of the capsules up and into the caps.

It will lock the body permanently into the caps and then remove the full capsules from the machine.

Step Five: Final Inspection Stage

You must inspect the quality of the capsules first before releasing them for polishing and storage.

Ensure that every capsule is in order by eliminating the faulty capsules from the good ones.

After that, you will transfer the good capsules to the polishing machine before packaging and storage.

18. What is a Semi-Automatic Capsule Filling Machine?

Semi automatic capsule filler machine

 Semi-automatic capsule filler machine

A semi-automatic capsule filling machine depends on automatic and manual parts to fill the capsules.

You will employ the services of a few professionals to assist in operating the manual parts of the machine.

19. What are the Advantages of Using a Semi-Automatic Capsule Filling Machine?

When using a semi-automatic capsule filling machine, you will experience the following benefits.

• You can use the machine in filling different filling materials such as pellets, powders, and granules.
• It is faster than a manual capsule filling machine since it provides automation to a particular degree.
• You can use a semi-automatic capsule filling machine for a medium scale of production in comparison to manual machines.
• The cost of purchasing and installing a semi-automatic capsule filling machine is lower in comparison to a fully automatic machine.
• In comparison to a manual capsule filling machine, you will eliminate the need of excess labor thus reducing production cost.
• Semi-automatic capsule filling machine is a faster and more accurate machine in comparison to a manual capsule filling machine.
• It is safe for you to use since it adheres to the safety qualifications and has parts that enhance the safety.
• It has more parts than a manual capsule filling machine and can perform activities such as polishing of capsules.
• It does not emit a lot of sound thus making it a more efficient machine for a peaceful working environment.
• Since the machine is semi-automatic, it is safer for you and your employees due to sensors and other safety features.
20. Does a Semi-Automatic Capsule Filling Machine Have Drawbacks?
Yes, a semi-automatic capsule filling machine has its disadvantages just like any machine would.
Here are the main disadvantages of the semi-automatic capsule filling machine.
• Since it is not fully automatic, you will have to hire extra personnel which might be costly.
• You will spend more money in the purchasing and installation of the machine in comparison to a manual capsule filler.
• You may have a lot of difficulty dismantling some parts of the machine thus posing difficulty in cleaning and maintenance.
• Due to the heavy weight and big size, you may not have the opportunity to work on a bench or move it around.
• You will also experience a lot of challenges integrating the machine with other machines since it is not fully automatic.
• Human laxity also reduces the scale of production thus you may not be able to realize full potential of the machine.

20. What are the main Parts of a Semi-Automatic Capsule Filling Machine?

Parts of semi automatica capsule filling machine

 Parts of semi-automatic capsule filling machine

A semi-automatic capsule filling machine comprises of different parts that enable efficient filling of capsules.

Here are the parts of the semi-automatic capsule filling machine that enhance its functionality.

• PLC Control System

You will use the PLC control system to configure and program the semi-automatic capsule filling machine.

You will key in the production specifications from the PLC control panel.

• Filling Auger

The filling auger is the main control system that determines the filling speed of the semi-automatic capsule filling machine.

It will determine how fast or how slow the semi-automatic filling machine will fill powders and pellets into empty capsules.

• Powder Hopper

The powder hopper is the main part of the machine where you will fill the powder or the pellets before filling process commences.

It has a particular design which assists in the dismantling of pellets and powder before filling process begins.

• Loading System

It is the part of the machine that will load empty capsules as well as the filling material and position them accordingly.

• Body and Caps Tray

This tray is in two parts which you can use to automatically separate the caps from the body of the empty capsules.

• Pneumatic System

This is the main air pressure system or compression drive that push the filler materials into the empty gelatin capsules.

• Filling Table

With a filling table, you can control the filling speed since it varies infinitely and allows for more accurate dosing.

• Transport System

This unit comprises complete with guiding rays and conveyor belts which guide capsules through the right channels.

• Capsule Opener and Closure System

This unit allows for a more accurate and faster rate of opening and closing empty capsules before and after filling.

21. How does a Semi-Automatic Capsule Filling Machine Work?

You will go through the following steps to perfectly execute the filling of empty capsules using a semi-automatic capsule filling machine.

Here is a step by step guide on how a semi-automatic capsule filling machine works.

Step One: Loading of Raw Materials

The first thing that you have to confirm is the condition of the machine which should be proper.

After that, you will load the empty capsules and the filling material into respective product hoppers.

You will power on the machine by pressing the start button for the machine to commence operation.

You should also key in the major operation parameters at the PLC control system to guide the operations of the machine.

Step Two: Separating the Body from the Caps

Through the delivery system of the machine, the empty capsules will move from the main capsule hopper.

The capsules align at right angles in the round capsule tray as it awaits the filling process.

Before the machine injects the filing material, you have to remove the caps from the body.

The capsule tray is in two parts consisting of the upper and the lower part.

The upper part holds the caps while the bottom part holds the lower body of the empty capsule.

You will manually remove the upper part and with it comes out the caps of the empty capsules.

The body of the empty capsules remain intact and moves around on a conveyor belt awaiting the filling process.

Step Three: Filling the Empty Capsules

The machine will initiate the flow of the filling material into the empty capsules which are at right angles.

The filling table will position the filling nozzles strategically above the empty capsules.

The tray will be in continuous motion as the filling material goes through the nozzles and into the empty capsules.

With the help of a dosing disk, the machine is capable of controlling the filling quantity and speed as accurate as possible.

As soon as all the capsules are full with the filling material, the machine will automatically retrieve the filling machine.

Step Four: Replacing the Caps

You will position the caps tray directly above the body tray that will push the caps onto the body of the capsules.

Apply a little bit of pressure at the compression zone so that the caps can fit perfectly onto the body.

Finally, you will discharge the full capsules from the machine for further inspection and packaging.

22. What is a Fully Automatic Capsule Filler Machine?

Fully automatic capsule filler machines are electromechanical encapsulation systems for high speed filling applications of empty capsules.

23. How many types of Fully Automatic Filling Machine are Available?

Fully automatic capsule filling machines are available in different types with different parts performing different functions.

Your choice of fully automatic capsule filling machine will depend on the type of capsule and inner fill material.

Implying that you have to have prior knowledge of the purpose and main application of a fully automatic capsule filling machine.

Here are the main types of fully automatic capsule filling machines:

• Soft Gelatin Capsule Filling Machine
• Tamping Pin Capsule Filling Machine
• Dosator Capsule Filling Machine

24. What is a Dosator Capsule Filling Machine?

Dosator capsule filling machine

Dosator capsule filling machine

This is a type of hard gelatin filling machine that you can use for mass production of clinical trials.

The most critical attributes of a dosator capsule filler machine is the high level of consistency and accuracy in dosing applications.

You can also use a dosator capsule filling machine to fill different tablets, powders, and pellets into capsules of different sizes.

25. What are the Advantages of Using a Dosator Capsule Filling Machine?

 Dosator capsule filling machine tooling system

 Dosator capsule filling machine tooling system

When using a dosator capsule filling machine, you will experience the following benefits.

• It is capable of obtaining different dosages and compacting them in one swift step in comparison to tamping filling machine.

This will result into a particular capsule which has a more homogenous density.

• You can easily modify the stress that you apply thus making it more application for the particular application.
Implying that different powders require different compressions thus prompting different modifications of stress application levels.
• It can fill different types of capsules in a variety of forms and quantities including granules, powders and pellets.
• You can use it in filling different sizes of capsules as well as respiratory blister packs due to rapid drug action.
• You can also modify the dosator capsule filling machine to fit a wide variety of your production needs.
• It also comes complete with different automatic sensors which will detect malfunctions thus protecting the machine.
• You can easily scale the filling process of the dosator capsule filler equipment during the filling process.
• Since it is fully automatic, you can integrate the dosator filling machine with other machines to form a complete production line.
• You don’t have to hire additional personnel except for the few since the machine is fully automatic.
• Using a dosator capsule filling machine is economical and save money and time due to its automatic nature.

26. What are the drawbacks of using a Dosator Capsule Filling Machine?

Despite the numerous advantages of the dosator capsule filling machine, you will also experience some setbacks.

Here are some of the disadvantages of using a dosator capsule filling machine.

• You will spend more in the original cost of purchasing and installing a dosator capsule filling machine.
• You also have to train your personnel on the basic aspects of operating, cleaning and maintaining a dosator capsule filling machine.
• The weight and the size of the dosator capsule filling machine will limit your chances of moving from place to place.

27. Which are the Main Parts of a Dosator Capsule Filling Machine?

A dosator capsule filling machine will function effectively with the help of the following parts.

Dosator capsule filler

 Dosator capsule filler

 Dosator c

 Dosator capsule filling principle

• Electrical System

The machine depends on electric power to power most of the functions.

The electrical system will provide, and control the amount of electric power flowing through the machine.

• Powder Bed

This is the main storage unit of the filling material which can be in the form of powder, pellets or tablets.

• Dosator Plunger

The dosator plunger compacts and locks the filling material (powder, tablets, pellets) into the dosator cavity.

• PLC Control System

This part comes complete with a touchscreen for programming, control and monitor all the machine operations.

• Dosator Cavity

This is the space where the filling material flows into as it is on transit to the filling station of the empty capsules.

• Dosator Pins

The dosator pins are capable of sucking mateial from the powder bed and ejecting the powder into an empty capsule.

• Automatic Lubrication System

This is the part of the machine which greases the moving parts of the machine.

It also lubricates the capsules appropriately thus making it easy to swallow.

• Pneumatic System

Using the pneumatic system, the dosator capsule filling machine is capable of sucking and ejecting the filling material.

• Automatic Sensors

With the help of automatic sensors, the machine is capable of determining different quantities of filling material.

It is also capable of determining faults in the machine thus eliminating the risks of damages on the machine and injuries.

• Transport System

It is composed of conveyor belts complete with guiding rails that transport the capsules from one station to the next.

• Capsule Trays

You will place all the empty capsule in the capsule tray before commencing the filling process.

You will also depend on it to open and close the capsules before and after the filling process.

28. How Does a Dosator Capsule Filling Machine Work?

You will be capable of controlling and monitoring the capsule filling machine with proper knowledge of how it works.

Here is a step by step guide on how a dosator capsule filling machine works.

Step One: Powering on the Machine

First, you should ensure the dosator capsule filler machine is in proper working condition.

As soon as you power the machine, you will allow it to rest in the operational mode as you configure it.

Key in all the filling specifications according to your filling requirements from the control panel.

Remember to fill the capsule trays with empty capsules and the powder bed with enough filling material.

Press the start button and allow the machine to commence the filling operations.

Step Two: Filling the Dosator

At this point the dosator will move to the material hopper of the machine to collect the filling material.

It will plunge into the powder and collect the right amount of filling material by sucking it in.

The cavity size within the dosator will depend on the dimensions of the plunger of the dosator system.

As that continues, the dosator will compress the powder and create more space for more powder.

During the compression process the filling material transforms into a slug.

After that, the dosator will move from the material hopper and straight to the position over the body of the capsules.

Step Three: Doctoring Dosator Tip

This is the point where you will confirm that the tip of the dosator is free of the filling materials.

You can clean it through doctoring process which gets rid of the excess powder from the tip.

Step Four: Opening Empty Capsules

During the filling up process of the dosator capsules, the machine also fills the capsule trays with empty capsules.

After that, the machine will move the capsule trays with the empty capsules straight to the filling station.

Using a vacuum system, the machine will separate the caps from the body.

It will be setting up the body for the filling process by placing at right angles.

Step Five: Filling the Body of the Capsules

The dosator pins are in a rotation mode where one side collects the filling material while the other fills the capsules.

As the full dosator plunges into the empty capsule, the other empty capsule will plunge into the filling material.

It will suck the material as the other side of the dosator releases the powder into the empty capsules.

The process continues until all the empty capsules are full.

Step Six: Replacing the Caps

After a successful filling process, the machine will replace the caps and lock the body into the cap.

You will then allow the machine to move the full capsules though other process such as sorting and packaging.

Clearly, the working principle of dosator capsule filler machine is quite simple and straightforward.

29. What is a Tamping Pin Capsule Filling Machine?

A tamping pin capsule filling machine depends on the tamping pin technology to fill empty hard gelatin capsules.

 Tamping

Tamping pin capsule filling machine

30. What are the Parts of a Tamping Pin Capsule Filling Machine?

The automatic tamping pin capsule filling machine consists of the following parts:

Tamping

 Tamping Pin Tooling System

• Tamping Pins

The number of tamping pins usually vary according to the type of machine but most machines have five.

This is the main part that will compress and fill the filling material into the empty capsules.

• Dosing Pan or Dosing Disc

This part has several holes on the surface which regulate the speed which the machine fills the empty capsules.

• Tamping Plate

The machine depends on the tamping plate to control the filling process.

It moves the holes of the tamping pin filling machine from one tamping pin to the next.

• Powder Hopper or Powder Bed

You will place the filling materials such as filling powders into the powder hopper or powder bed.

Apart from that, it comes with level sensors which will alert you when the level is too high or too low.

It has a screw feeding mechanism which that feeds the capsule filling system with the filling material.

• Mechanical Drive System

This part of the machine creates a linear, rotary, and oscillatory motion which initiates all the movements within the machine.

It depends on motors, gears and conveyor systems to initiate movement.

• Lubrication Unit

The pneumatic system has a compression air jet which pushes the filling material straight into the empty capsules.

• Electrical System

This is the main source of power for the tamping pin capsule filling machine.

It provides, controls. And regulates the amount of power flowing through the parts of the machine.

• Capsule Hooper

The capsule hopper is the part of the machine that holds all the empty capsules before filling.

It has level sensors that will alert you if the supply of empty capsules is running low or is in excess.

• Capsule Feeding Unit

The capsule feeding unit allows the movement of empty capsules from the capsule hopper to the filling station.

It controls the number of empty capsules according to the production specifications.

• Rotary Turret

The rotary turret is always closed and is responsible for the alignment and orientation of empty capsules before filling.

It also controls the quantity of filling material returns excess filling material back to the product hopper.

• Vacuum Unit

This is the main connection unit between the powder loading port and the powder hopper.

It also connects the capsule loading port and the capsule hopper.

Apart from that, it is responsible for separating the caps of the empty capsules from the body.

• Capsule Filling System

This part depends on level sensors and filling funnels to accurately fill empty gelatin capsules.

It will release and cut the supply of filling materials to the empty gelatin capsules.

• PLC Control System

This is the main part where you will key in the right filling specifications according to your filling requirements.

It comes complete with a touch screen that allows you to monitor and control all the filling operations.

• Automatic Loading Device

It has two automatic lading devices which will fill the powder and capsule hopper automatically when levels are down.

• Interlock Safety Door

It is one of the safety measures which will trigger shut down of the filling machine in case of any problem.

For instance, if you open the safety door while the machine is in operation, the machine will automatically shut down.

31. What are the Advantages of Tamping Capsule Filler?

A tamping capsule filler will offer you the following advantages when you are using it.

• You can easily operate the machine as well as clean and maintain it at very low costs.
• It has adjustable settings that allows you to configure the filling levels of the capsules.
• Most parts of the machine have tight enclosures thus preventing the entry of dust and other foreign materials.
• It is capable of filling empty capsules very fast since it is automatic thus saving time and energy.
• It also has automatic sensors which will automatically warn you of imminent danger.
It will also help in the predetermination of filling levels allowing you proper and more accurate filling levels.
• The parts of the machine ensure integrity of the capsules thus leading to minimal damage of the capsules.
• You can integrate the machine with other machines thus forming a complete production line.
• It also complies to the right quality standards including cGMP and CE allowing for highest quality standards.

32. What are the Disadvantages of Tamping Capsule Filling Machine?

Just like any other machine the Tamping Pin capsule filling machine has its drawbacks.

Here are the main drawbacks of the tamping pin capsule filling machine.

• Purchasing and installation cost of the tamping pin filling machine is often high in comparison to other machines.
• You need to have a lot of floor space for the installation of the machine since it is heavy and big in size.
• Due to the weight and size of the machine, you may not be able to move it from one place to another.
• You can only use the machine in filling solid materials thus eliminating the chances of filling suspensions, liquids and semi-solids.

33. How does a Tamping Pin Capsule Filler Machine Work?

The working principle of tamping pin capsule filling machine depends on the following steps:

Step One: Capsule Refraction for Proper Orientation

First, after confirming the machine is in proper working condition, you will initiate the loading of the capsules and filling material.

Power the machine and it will begin the orientation process to align the empty capsules properly awaiting filling.

The process will begin by allowing the empty capsules moving from the capsule hopper through the vacuum system of the machine.

Step Two: Opening of Empty Capsules

As it passes through the vacuum system, the machine will separate the cap from the body of the capsule.

Since the capsules are at right angle, they will automatically move to the filling station.

The machine will move the caps to a different location as it awaits the filling process to complete.

Step Three: Actual Filling Process

Once at the filling station, the machine initiates the dosing disc which rotates in a circular manner at a controlled speed.

As it flows under the powder hopper, the powder flows directly into the holes of the dosing disc.

At the same time, the tamping pin compresses the powder thus creating more space for more powder.

More powder flows into the holes as the dosing disc remains in a continuous rotary motion.

The process continues until it reaches the last tamping pin ensuring the holes are full with the filling material.

Through the dosing plate, the machine will release the powder into the empty capsules and scraps off the excess powder.

Step Four: Covering and Sealing the Capsules

With the help of the rotary turret, the machine will move the full capsule to the capping station.

Apart from that, the rotary turret will also ensure that the excess filling material moves back to the material hopper.

The machine will close the capsules in a continuous rotary motion that places and locks the caps onto the body of the capsules.

Finally the machine will eject the full capsules and transport them for further actions such as sorting and polishing.

34. What is a Softgel Capsule Filling Machine?

This is an electromechanical device that you can use to hermetically fill soft gelatin capsules with different materials.

In this case, you will use a different type of fill material which can either be liquid, suspension or semi-solid.36. What are the

Advantages of a Softgel Encapsulation Machine?

You should consider using a Softgel encapsulation machine due to the following benefits.

Softgel encapsulation machine

 Softgel encapsulation machine

• It fills soft gelatin capsules which are much easier to swallow due to their soft lubricated nature.
• It increases the shelf life of the active ingredients by ensuring that the filling materials remain stable.
• The machine will create a hermetic seal which is water proof, and airtight thus keeping the inner fill material safe.
• Apart from that, it is the only machine which can hermetically seal Softgel capsules with liquid and semi-solid materials.
• You can use the machine to produce Softgel capsules of varying shapes and in different sizes.
• You can be sure of accurate and efficient filling of the Softgel capsule inner fill materials using the Softgel encapsulation machine.
• Since the machine is fully automatic, you will not need to hire extra personnel to assist in the encapsulation process.
• You can use the machine for large scale production since it encapsulates Softgel capsules at a very high rate.

35. What are the Disadvantages of a Softgel Capsule Filling Machine?

Despite the numerous benefits of the Softgel encapsulation machine, it also has its demerits.

Some of the disadvantages of Softgel capsule filling machine include:

• You have a limit of filling particular types of inner fill material such as liquids, semi-solids and suspensions.
• You cannot use a Softgel encapsulation machineto fill hard gelatin capsules with powders, pellets or tablets.
• The initial cost of purchasing and installation of a Softgel capsule filling machine is high.
• You do not have the luxury of moving it from one place to another since it is heavy and big in size.

36. Which are the Main Parts of a Softgel Capsule Filling Machine?

A Softgel capsule filling machine has different parts that it depends on to fill soft gelatin capsules.

Here are the main parts of a Softgel encapsulation machine:

 Parts of Softgel encapsulation machine

Parts of softgel encapsulation machine

• Product Material Tank or Medicine Hopper

This is a container that is made of stainless steel that you can use to hold the filling material which you wish to encapsulate.

It has a special design which seamlessly allows the filling material to flow to the material feeding pump.

• Material Feeding Pump

This part of the machine sucks the filling material allowing it to flow freely from the medicine hopper or product material tank.

It also injects the filling material straight into the injection wedge.

• Injection Wedge

This part of the machine heats the gelatin web while injecting the filling material as it moves to the die cavity.

It comes complete with different unique features among them being:

i. Electric or water heating system

ii. Sensors which coordinate the movement of the injection wedge

iii. Shut off valve systems which close the web tube

• Gelatin Mixing and Melting Tank

You will heat and mix all the ingredients of making a soft gelatin shell inside a gelatin mixing and melting tank.

The gelatin mixing and melting tank consists of clamps, wall jackets, as well as steel valves which assist in gelatin preparation.

You should consider the following factors while looking for a good gelatin melting and mixing tank.

i. Type of material for the machine which should be stainless steel

ii. Power rating of the gelatin mixing and melting tank

iii. Dimensions of the machine in terms of size, weight and capacity

iv. Proper working temperature range of the gelatin mixing and melting tank

• Gelatin Spreader Box

This is the place where the machine will hold molten gelatin, spreading it into a thin layer for making gelatin shell.

A good Softgel encapsulation must have two gelatin spreader boxes on the left and the right side as well.

• Cooling Drum

A Softgel encapsulation has two cooling drums on the left and the right side which cools and solidifies gelatin web.

Cooling drums are often in constant motion in the web direction and initiates the cooling effect as the web flows.

• Lubrication System

The system consists of oil rolls and lubrication rollers for the application of lubricants on both sides of the gelatin web.

The lubrication system will prevent the gelatin ribbon from breaking as it flows from one station to the next.

• Tooling System

It consists of two die rollers which assist in the process of encapsulation of Softgel capsules.

Apart from that, the tooling system is responsible for the following:

i. Shaping Softgel capsules

ii. Continuous feeding and filling of the Softgel capsules.

iii. Hermetical sealing of soft gelatin capsules.

iv. Cutting the soft gelatin capsules from the ribbon after the encapsulation process.

• Discharge Chute

This is the part where the machine will eliminate the fully formed soft gelatin capsules.

• Conveyor Belt

It is responsible for moving the capsules from the encapsulation stage to subsequent stations for further processing.

• Control Panel

You will control and configure the soft gelatin encapsulation machine using the control panel.

It comes complete with a touch screen which you can use in monitoring the encapsulation process.

• Drying System

The drying system is composed of different mechanisms such as drying trays and tumble dryers which eliminates excess moisture.

37. How Does a Softgel Capsule Filling Machine Work?

In the operation of a Softgel encapsulation machine, you will go through the following steps:

Step One: Gelatin Preparation

With the right gelatin formulation, you will begin by mixing all the ingredients in a gelatin melting and mixing tank.

Before you proceed, make sure that the machine is in proper working conditions.

After that, you will pour all the ingredients in the gelatin mixing and melting tank.

Power the machine on after proper configuration of the system from the control panel.

The melting and mixing tank will melt, mix and thoroughly blend all the ingredients until it forms a thick syrup.

You will direct the machine to allow the thick syrup to flow to the spreader box, cooling drum and die roller system.

Step Two: Filling Material Preparation

In this stage, you will prepare the filling material which can either be liquid, semi-solid or suspension.

It also takes the form of an oil base depending on the final requirements of the capsule.

The machines that you will use include hammer mills, granulators or fluid bed dryers, and processing tank.

You will mix the ingredients in the processing tank which heats, stirs and blends the ingredients to form a homogenous mixture.

The filling material will flow to the injection wedge straight from the filling material hopper.

Step Three: Actual Encapsulation Process

At this point, the filling material, as well as the soft gelatin shell, come together to form a complete capsule.

At the die roller system, the gelatin ribbons from the right and the left side meet to form a unique capsule shape.

At the same time, the machine will also feed the filling material to the Softgel ribbons.

The gelatin ribbons will encapsulate the filling material leading to the formation of a complete capsule.

The shape of the Softgel capsules will depend on the shape of the die roll cavities.

After the formation of the Softgel capsules, the machine will cut the capsules into individual pieces.

Using the stripper rolls and the brush, the machine will remove the capsules that might stick to the die rolls.

It also removes the capsules that stick to the gelatin web making sure that nothing stays behind.

Step Four: Further Processing

The final stage involves drying, sorting and cleaning of the capsules.

The machine will move the Softgel capsules on conveyor belts to the tumble dryer.

You will load the soft gelatin capsules on drying trays and move them to the drying tunnels.

Due to excess heat in the drying tunnels, the Softgel capsules will lose a considerable amount of moisture.

After that, you will move the Softgel capsules from the drying tunnels and into the sorting machine.

The machine will eliminate capsules with defects and allow the proper capsules to proceed to cleaning and subsequent packaging.

38. What are the different Sizes of Capsule Fill Weights?

Depending on the dose requirement and the formulation, you can decide on the weight and size of the capsules.

You can also determine the capsule size with information on contentment formulation and dosage weight.

Apart from that, you will determine the weight by looking at the volume and the density of the filling material.

For instance, in a powder and granulate mixture, tapped density assist in determining size of capsule.

Bulk density of micro-pellets and pellets will also assist in the determination of the capsule weight and capsule size.

The capsule size ranges from 000 which is the biggest to 5 which is the smallest capsule size.

Capsules sizes

Capsule sizes

39. What is the Quality Compliance for capsule Filling Machines?

When purchasing a capsule filling machine, you have to ensure that it adheres to the right quality standards.

Quality compliance is the adherence of the machine to particular industry standards on safety, reliability and quality.

Here are the main quality compliance certifications that you need to adhere to.

• cGMP for the current good manufacturing practices
• ISO certification for the International Standards Organization
• CE which is in charge of the electric certification of the machine
• FDA which is the food and drug administration certification

40. What are the Conditions Suitable for Storage of Capsules?

The storage conditions that you choose to work with will depend greatly on the types of capsules you produce.

For Softgel capsules, you will store it in humidity-controlled environment to reduce the loss of excess moisture.

In that case, you will have to monitor the temperature and humidity fluctuation to create an ideal storage environment.

You should also note that different types of capsules also have different storage conditions thus affecting your choices.

41. Which is the Best Material for Making a Capsule Filling Machine?

The best material that you can use in making a capsule filling machine is stainless steel.

It is a durable material with very minimal chances of contamination.

It is more hygienic thus suitable for the capsule filling machine.

42. What is a hard Gelatin Capsule Filling Machine?

A hard gelatin capsule filling machine is a device that you will use in the filling of hard gelatin capsules.

You can use the machine to fill powders, pellets and tablets into empty hard gelatin capsules.

43. What are the different Formulations can you Fill in Capsules?

Content of hard gelatin capsules

Figure 22 Content of hard gelatin capsules

You can fill different formulations in capsules depending on the type of capsules you are filling.

Here are the formulations that you can fill in different types of capsules.

In hard gelatin capsules, you can fill the following formulations:

• Powder formulations
• Pellet formulations
• Tablet formulations

In soft gelatin capsules, you can only fill the following:

• Liquid formulations
• Semi-Solid formulations
• Suspension formulations

46. What Factors Affect the Efficiency of Capsule Filler Equipment?

There are different factors in a capsule filling equipment that can affect the efficiency of the machine.

Here are the main factors which you need to consider when looking at the efficiency of the machine.

1) Type of Machine

In this case, you will look at the level of automation of a particular capsule filling machine.

For instance, a fully automatic capsule filling machine is more efficient in comparison to a manual capsule filling machine.

Implying that, fully automatic capsule filling machines have better, faster and more accurate filling in comparison to manual capsule filling machines.

2) Dimensions of the Capsule

In this case, you will look at the weight as well as the size of the capsule filling machine.

The bigger and heavier a capsule is, the more work it requires and thus prompting more work from the machine.

Implying that the machine will take more time to fill up the empty capsules thus affecting the efficiency of the machine.

3) Level of Maintenance

The more you maintain a capsule filling machine, the higher the efficiency.

Frequent maintenance and cleaning of a capsule filling machine will lead to better working machine thus better efficiency.

4) Working Environment

You should always maintain a particular working environment that is suitable for the successful operations of the machine.

The more conducive the environment, the higher the efficiency of the machine.

44. How Does a Hard Gelatin Capsule Filler Compare to Softgel Encapsulation Machine?

Hard gelatin capsule filler

 Soft gelatin capsule filler

 Hard gelatin capsule filler

You will use a hard gelatin capsule filler to fill hard gelatin capsules with different types of formulations.

The main formulations that you will fill within a hard gelatin capsule are powders, pellets, and tablets.

On the other hand, you will use the Softgel encapsulation machines to fill soft gelatin capsules.

The main formulations that you will fill using a Softgel encapsulation machine include liquids, suspensions and semi-solids.

Apart from that, Softgel encapsulation machines are fully automatic while some of the hard gelatin filling machines are not.

You can find hard gelatin capsule filling machines in manual and semi-automatic conditions.

Additionally, the working principles of both machines vary considerably.

Softgel encapsulation machines fill and hermetically seal the soft gelatin capsules at the same time.

On the other hand, a hard gelatin capsule filling machine will make the capsule shells separately from the filling material.

45. What is the Difference between a Dosator Capsule Filler Machine and Tamping Pin capsule Filler?

Dosator capsule filling system

Dosator capsule filling system

Tamping pin capsule filling system

 Tamping pin capsule filling system

You need to have a proper understanding of a tamping pin capsule filling machine and dosator capsule filling machine.

Here are the main differences and similarities between the dosator and tamping pin capsule filling machines.

• In both dosator and tamping pin capsule filling machine, you will fill empty hard gelatin capsules using powders, pellets, and tablets.

On the same note, both machine s will turn the filling material into slug before actual filling process.

• You can also engage the automatic capsule filling capabilities in both machines since they are available in fully automatic versions.
• Due to the automatic nature, you will e able to monitor and program both machines accordingly.
The major differences between the two machines include:
• You can use the dosator capsule filling machine in micro-dosing of capsule which you cannot perform with tamping pin capsule filler.
• Both machines have different working principles which they depend on in filling different types capsules.

The tamping pin capsule filling machine depends on a dosing disc and numerous pins to efficiently fill a capsule.

A dosator filling machine depends on one pin, one dosator and dosator pin to fill the hard gelatin capsules.

46. Which Support Equipment do you Use during Capsule Filling Process?

You will need the support of other equipment to assist you in the capsule filling process.

Here is the main support equipment that you can use in the filling of different types of capsules.

Support Accessories for Preparation of Materials

The main types of equipment that you will use in the preparation of materials include:

i. High Shear Granulator Machine

ii. Hammer Mill

iii. Vibro Sifter

iv. Bins and Drums

v. Fluid bed processor

Equipment for Final Capsule Processing after Filling

Some of the equipment that you will use after filling the empty capsules include:

i. Drying Systems

ii. Capsule sorting machines

iii. Capsule Printing Machine

iv. Capsule Polishing Machine

v. Capsule Packaging Machine

47. When should you use Dosator Capsule Filler and not Tamping Pin Capsule Filler?

You should use the dosator capsule filling machine when micro-dosing capsules which is not possible with tamping pin capsule filling machines.

48. What is Micro-dosing in Capsule Filling Process?

Micro-dosing in capsule filling process is the process of filling very small capsules using small quantities of filling materials.

You will use a dosator capsule filling machine to enable you to fill micro-doses of capsules.

49. How Does the Dosing Disc Affect Capsule Material Formulation?

The dosing disc has multiple holes on the surface which assist in the regulation of the speed of filling materials.

Apart from that, it assists in compacting the material formulation to form a slug.

50. How Does the Dosing Disc Determine Capsule Sizes?

Section of the dosing disc

Section of the dosing disc

Dosing discs are responsible determining the amount of fill materials that flow into respective capsules.

It is available in different sizes which can accommodate different sizes of empty capsules.

It will also determine the amount of fill materials that you will fill into the different sizes of fill materials.

51. How Does Dosing Disc Affect Tooling Component?

The dosing disc affects the tooling components by controlling the weigh as well as the dosing of the filling materials.

It is capable of manipulating the tooling system to produce filling materials of different weight and quantity.

52. What are the New Innovations in the Capsule Filling Industry?

As time goes by, so does the development of technology advance.

In that case, you will come across new technological advancements in capsule filling technology such as:

• Technology that enhance Efficiency, Performance and Productivity

Some of the new innovations that you will use in improving efficiency, productivity and performance are:

i. Colored HMI touchscreen that improves the controlling and monitoring experiences.

ii. Enclosures in the electrical, dosing and moving systems for efficient and consistent capsule filling.

iii. Vacuum cleaning system that enable efficient and faster cleaning mechanisms.

iv. Automatic lubrication systems which automatically lubricate the capsules.

v. Variable frequency driving systems that control the speed of the moving parts such as the motor.

• Technology that Improves Safety of the Machine and the User

There are different types of new innovations that you can use to improve your safety and that of the equipment.

Here are the main types of new innovations:

• Use of transparent polycarbonate sheets with door check sensors to improve visibility and safety.
• Alarm systems that go off when the capsule and filling materials levels go down.
• Emergency switches that you can use to stop the machine in case of emergencies.

53. What are the Working Requirements of Capsule Filling Equipment?

The main requirements for capsule filling machine to operate include the following:

• All the functional and technical requirements
• Operational requirements of the capsule filling machine.
• Specifications of the control systems including different forms of outputs, interfaces, and needs.
• Power requirements of the machine
• Safety of the machine

54. Which are Capsule Filler Validation Documentations?

Capsule filling machine validation documentation that you should consider having include:

 Capsule filling machines

 Capsule filling machines

1) FAT Factory Assessment Test Documentation Validation

This involves doing thorough tests at the factory before releasing the machine for installation and operation.
After that, you will receive a full document to prove full factory assessment test is complete and satisfactory.

2) IQ Documentation Validation

You will receive an IQ documentation validation after performing a thorough inspection on the machine after installation.

3) OQ Documentation Validation

You will an OQ documentation certificate after confirming that the machine is in proper operational condition after installation.

55. Does SaintyCo Offer help in Installation and Commissioning of Capsule Filler?

Yes, SaintyCo will offer assistance in the commissioning of a capsule filling machine.

It will make sure that you have an expert to assist in the commissioning of the capsule filling machine.

56. Does SaintyCo help in Making a Custom Capsule Filling Machine?

Yes, you will get help from SaintyCo team of designers and engineers who have been in the industry for a long time.

They will make sure that you get a custom filling machine that is capable of filling capsules according to your specifications.

57. How Do You Troubleshoot Capsule Filler?

To identify the problem that id derailing proper filling of capsules, you will troubleshoot the machine.

Here are some of the problems and solutions you will find.

Automatic capsule filling machine

Automatic capsule filling machine

• Inability of Capsule to Flow into the Magazine

This can be as a result of slow speed of operation, damaged capsules, incorrect baffle plate positions and damaged magazines.

You can solve this problem through removing the damaged capsules and adjusting the speed of operation.

You should also position the baffle plate appropriately and replace damaged magazines.

You can experience this kind of problem due to the following reasons:

i. Slow speed of operation of the machine

ii. Damage of capsules blocking flow of capsules

iii. Incorrect baffle plate positioning

iv. Damaged magazine preventing flow of capsules

You can solve this problem by adjusting the speed of the operations and removing the capsules blocking the flow of capsules.

You will also position the baffle plate accordingly and replace the damaged magazines.

• Damaging of capsules during the Loading Process

This can be a result of incorrect rectifier alignment block and incorrect alignment of the bushes.

You can use an alignment gauge to properly align the rectifier block and bushes.

• Failure of Capsule Separation

This can be the result of insufficient pressure in the vacuum that cannot remove the caps of the empty capsules.

The filters of the capsule filling machine might also leak leading to low pressure in the vacuum.

You can sort this by replacing the vacuum system with a properly functioning vacuum system.

• Failure to achieve Target Weights

You might not achieve the weights that you are targeting due to insufficient slug binding, an insufficient flow of powder.

You can sort the problem by ensuring slug binding is in proper condition and use a flap to push the powder.

58. How do you Maintain Capsule Filler Machine?

To increase the efficiency and durability of the capsule filling machine, you must perform proper maintenance.

You can maintain a capsule filling machine by regularly cleaning all the parts of the machine, especially after daily operations.

You will also make sure that you lubricate the moving parts frequently to reduce friction and damage on the machine.
Remember to replace the filters and worn out parts of the machine on a regular basis.

59. How Does Vegetable Capsules Compare to Gelatin Capsules?

Figure 30

Vegetable capsules are the kind of capsules that you will consume as a vegetarian.

The main ingredient for making vegetable capsule shells come from vegetable products.

Gelatin capsules, on the other hand, come from animal products and suitable for non-vegetarian consumers.

Despite the differences they also have their similarities especially on the types of filling materials.

60. What are Delayed Release Capsules?

Delayed-release capsules are the type of capsules which will not disintegrate in the acidic stomach conditions.

They often disintegrate in the alkaline conditions of the duodenum.

It is proper for you to use in case you suffer from acute stomach irritations when you consume other capsules.

61. Which is the Best Capsule Filling Machine for Sticky Powders and Liquids?

The best capsule filling machine that you can use to fill sticky powders and liquids is the Softgel encapsulation machine.

The machine has the capability of handling sticky powders and liquids and encapsulate them within gelatin shells.

62. Is it Possible to use one Capsule Filling Machine for all Sizes of Capsules?

Yes, you can use one capsule filling machine for all sizes of capsules.

All you need to change from time to time is the tooling system of the capsule filling machine.

Automatic capsule filling machines will automatically change the tooling system according to capsule sizes.

63. What is Capsule Fill Weight?

Capsule fill weight is the amount of filling material that you will use in the filling of one capsule.

It does not include the weight of the capsule shells.

67. Can You Use Capsule Filling Machines in Filling Tablets and Pellets?

Yes, you can use capsule filling machines in filling tablets and pellets.

You will the dosator and tamping capsule filling machine to fill pellets and tablets.

Softgel capsule filling machine is the only exception which does not fill tablets and pellets.

64. What is a Liquid Sealing and Band Sealing Line?

You will require a liquid sealing and band sealing line to completely seal the capsules.

It is a line of sealing materials which ensure that the content of the capsules is secure.

69. How Much does a Capsule Filling Machine Cost?

The cost of a capsule filling machine will vary according to the type and design of capsule filling machine.

A manual capsule filling machine is less costly and will cost around 1000 to 3000 dollars

Semi-automatic capsule filling machines are more costly ranging between 10,000 to 25,000 dollars.

Fully automatic capsule filling machines are the most expensive ranging between 30,000 to 50,000 dollars.

65. What are the main Features of a Capsule Filling Machine?

A capsule filling machine comes with particular features including:

Softgel capsule filling machine

Softgel capsule filling machine

• High speed capsule filling based on the type of machine you are using
• Ultra-quiet operations which eliminate excess noise
• Stainless steel material which is more hygienic and reduces contamination of the capsules
• Digital control panels with a good human machine interface for easy configuration and monitoring.
• Presence of an auger which regulates the rate of filling powder
• Special design that allows for proper changing of parts

66. How Can you use Capsule Filling Machine to Skyrocket your Business?

You can use a capsule filling machine to skyrocket your business by considering the following factors:

• Choosing high quality and reliable capsule filling machines
• Considering capsule filling machines with latest form of technology
• Learning how to operate the capsule filling machine on different levels
• Knowing how to troubleshoot and maintain a capsule filling machine in case of a problem
• Ensure that you follow the right installation procedures during the installation process.
• Consider looking at the future prospects of a capsule filling machine.
• Using efficient support equipment for capsule filling machines
• Ensuring capsules filling machines comply with the right quality standards
• Exploring different options that you can use in the process of filling different types of capsules.
• Frequently testing the capsule filling machine
• Hiring trained personnel to handle the operations of the capsule filling machine
• Keeping in touch with the capsule filling machine suppliers for more updates.

67. At what speed does a Capsule Filling Machine Operate?

Capsule filling machines operate at different speeds depending on the type of machine you are using.

The speed of the capsule filling machine is often in terms of the number of capsules it can fill in a specified time.

In a fully automatic capsule filling machine, you will be able to maintain a speed of 60 spm.

It can also be lower or higher depending on your production specifications.

You can get machines that are capable of filling 180,000 capsules in an hour depending on the speed.

68. Which Capsule Filler is suitable for DIY Projects?

You can use a manual capsule filling machine to perform a DIY project.

It is the kind of machine that you can use domestically to fill hard gelatin capsule with your personal filling materials.

74. Which Safety FeaturesDo Capsule Filler Machines have?

A capsule filling machine comes complete with its own safety features to protect you and the machine as well.

Here are some of the safety features that you will find in a capsule filling machine.

• Use of transparent solid polycarbonate sheets with interlocks that enclose the dosing section.
• Alarm systems that will go off in case the machine detects a problem.
• It also has sensors which will automatically detect and warn you if impending danger.
• Apart from that, the machine has automatic kill switches that will automatically stop it from running.

69. What is Capsule Filler Machine Specification?

Capsule filling machine specifications are the factors that you will consider before making a purchase of a capsule filling machine.

They may include production capacity, dimensions, power consumption, installation requirements, etc.

You should be able to include all these in the user requirements specification (URS) for capsule filler machines.

70. Do Operating Capsule Filler Machines Require Special Training?

Yes, you will have to go through special training to operate a capsule filling machine accordingly.

Your supplier may offer to train you and other workers on the best way of handling a capsule filling machine.

This will also involve how to clean and properly maintain the machine.

71. How Fast Do Gelatin Capsules Dissolve?

Softgel capsules

 Softgel capsules

Gelatin Capsules can dissolve in various times depending on the conditions.

If the conditions are right like the ones in the stomach, gelatin capsules will take around 30 mins to dissolve.

There are other capsules which have delaying properties and will dissolve in alkaline conditions.

You will have to wait longer for these capsules to actually dissolve.

72. How do you Fill Capsules with Essential Oils?

You will use the Softgel encapsulation machine to fill capsules with essential oils.

The working principles of the Softgel capsule filling machine is the most essential one for filling essential oils.

73. How can you Stop Capsule from Leaking?

You can stop capsules from leaking by ensuring that you get the ingredient combination right.

This will lead to the formation of a strong gelatin wall that is not likely to leak.

74. How Long Will It Take for Vegetable Capsules to Dissolve?

A vegetable capsule will take a little longer to dissolve in comparison to the gelatin capsules.

On that note, a vegetable capsule will take between 25 to 50 minutes to actually dissolve.

75. Can Softgel Capsules Break Easily after Filling?

It is important to handle Softgel capsules with care to avoid breaking under intense pressure.

It is possible for the Softgel capsules to break but that will require intense pressure.

Softgel capsules have special ingredients that will prevent the capsule from easily breaking.

76. What are Common Capsule Defects during the Filling Process?

During the filling process, you may encounter some capsule defects such as:

• Different shapes which are not in accordance to the particular shape you intended
• Different weights of the capsules
• Different sizes of the capsules
• Damages and scratches on the capsules.

Hard gelatin capsules defects

 Hard gelatin capsules defects

 Softgel capsules defects

 Softgel capsules defects

77. How can you Choose Capsule Filler Equipment?

You can choose capsule filler equipment by looking at specific technical specifications.

Some of the technical specifications to look at include:

• Dimensions of the machine in terms of size and weight of the machine
• Level of automation of the machine which can either be manual, semi-automatic and fully automatic.
• Speed of the machine will depend greatly on the level of automation
• Types of inner fill materials as well as type of gelation capsule
• Cost of the machine
• Reliability and efficiency of the machine
• Level of technology on the machine which should include the latest form of technology in the market.