Tablet Counting and Filling Machine: The Complete Buying Guide

A highly efficient tablet counting and filling machine will save you from grappling with the problems of counting and filling your tablets.

Today, I will take you through a series of guidelines on how to selectively choose and acquire a suitable machine for your pharmaceutical needs.

Together with an in-depth look at the varieties, parts, working principles, technical specifications, upcoming technologies, troubleshooting of the machinery among other details; I am confident you will enhance your tablet counting and filling industry.

Let me now take you through all these.

What is a Tablet Counting and Filling Machine?

A Tablet counting and Filling Machine is a versatile assembly of systems that work as a unit to accurately count pharmaceutical and food products.

These products include tablets, coated tablets, pills, hard and soft gelatin capsules.

Besides, the device is capable of precisely filling the bottles by use of a dual nozzle.

Tablet Counting and Filling Machine

During the filling process, there is little or no spillage of contents.

This is because of the air cylinders at the stage position and changes the bottles before filling takes place.

Note that, apart from the pharmaceutical and food industry, this machine is also applicable in the health care, agriculture, and chemical engineering industries.

More of this technique we shall discuss under the working principle.

Filling Tablets in a Bottle

One thing is evident, thanks to the sophisticated, intelligent sensors, you can achieve a high degree of count accuracy with this machine.

Of course, you will come by several designs of these machines in the market.

Now, you might be wondering about where you can use the tablet counting and filling machine.

In short, you will need this equipment alongside tablet compression machine.

Moreover, why do you even need it?

Applications of Tablet Counting and Filling Machines in the Pharmaceutical Industry

Do you know that Tablet Counting and Filling is a necessary procedure in the pharmaceutical industry?

Indeed, you have to be sure about the quantities of your productions.

Besides, medicines are very crucial to people’s health, and thus you have to be sure of their numbers because it would translate into the dosage given to patients.

Tablets in Bottles

Above all, assessing the tablet counts is essential for analyzing your production rate.

The numbers are significant when it now comes to the economic perspective of your business.

Surely, all production activities boil down to financial worth.

With this machine, you can opt for one with an advanced vibration, several channel feeders, computerized, automatic scanning capabilities, and fully automatic one.

All these specifications would ensure that you achieve your tablet counts at extreme speeds, without unnecessary expenses.

Interestingly, with this machine, you’re open to dealing with all the basic, irregular shapes, varied sizes of pharmaceutical products.

What are the other Applications of Tablet Counting and Filling Machines?

Aside from the pharmaceutical industry, you can as well require the services of this machinery in the following sectors.

• Food Industry
• Health care sector
• Chemical Engineering

Let’s have a little discussion about each.

· Food industry

Recently, there is full acceptance of food gelatins and capsules.

These products carry essential nutrients for the human body.

Food Supplements in Bottles

Consequently, technicians increasingly adopt the use of tablet counters and fillers to optimize the processing of food gelatins and capsules.

· Health care

This another sector that reaps big due to the counting and filling properties.

Most health care products, especially those in bottles such as ointments, require precise filling up to certain degrees and level.

Tablet Drugs in Bottles

With such much-needed precision, which other proper equipment would be suitable?

· Chemical Engineering

Chemistry strictly depends on chemical analysis.

Negligible amounts of elements have a devastating impact on the overall composition of a chemical.

Tablet Chemicals in Bottles

Therefore, you can entirely rely upon this equipment to achieve such a high level of the desired accuracy in filling.

With such information, let’s look at the reasons why you need the Tablet counting and filling machine.

Benefits of Tablet Counting and Filling Machine

As we have already seen, the counting and filling machine is very popular.

Moreover, it’s applicable in a wide range of industries just as we discussed earlier.

The reasons for such popularity only lie in the specific advantages that come with this machine.

Above all, there is a need to reverse the conventional way of hand counting to eliminate errors and other compromising issues.

The only way to deal with that is by use of an automatic counting machine.

For the sake of our discussion, we shall take into consideration the top seven benefits and reasons why you need this state-of-the-art device.

Tablet Filling, Counting, and Capping – Photo Courtesy: Packaging Valley

Let’s look into that.

i. It is cost-effective

As opposed to the hand counting technique which exhausts the employee’s time that would be otherwise vital in other competitive ways, an automatic way of counting would save both labor costs and time.

ii. Highly precise and not liable to errors

Imagine achieving a counting error of less than 1%.

Yes, that’s what you get when you use such a counting device.

This level of accuracy comes from advanced design and technology in construction.

iii. Highly time-efficient

Time is vital; the equipment gives you space for doing other tasks as it runs.

Besides, there’s no stoppage and starting due to errors.

Above all, the machine fills the bottles to preset degrees.

iv. Fast and effective

The tablet counting device is highly reliable for bulk processing.

Most of them operate at a speed of counting and filling up to 1000 of the products per container.

v. More comfortable and efficient mode of operation

With the use of a programmable logic controller, optimization of the service is at its peak.

You can as well follow up the processes through the Human-machine interface.

vi. Compact and steady

The equipment exists in a single unit.

The monoblock stand-alone carries out both the tablet counting and filling operations.

Also, there’s no need for a change of parts during the recount.

vii. The machine is available in various models

You have got the freedom to select suitable equipment from the 8 – 12-16-24-32 channels.

Selection would largely depend on your production requirement.

Some features are customizable too depending on customers’ needs.

Next, we look at another critical aspect of our discussion.

Tablet Counting and Filling Machine Quality Standards

The overall increased demand for the construction of equipment that enhances both the quality and quantity of productions has led to the general rise in varieties of tablet counting and filling machines.

With that in mind, it will be quite challenging to buy an appropriate one.

However, for you to make the right selection, it’s paramount for you to look at the quality specifications of each.

After that, you may pick on the one that adheres to all the necessary set standards.

So, we need to look at the must-have standards for the verification of the authenticity of the machines.

cGMP Tablet Counting and Filling Machine

Check out for the following.

• Machine should be of modular design and the cGMP compliant.
• Look out if the conveyor construction is of the AISI 304.
• Gearbox and motor of the tablet counting and filling machine should be CE Certified.
• Material for the construction of the frame of the machine is that of AISI 304 sheet.
• Noise level production of the machine need to be below 70DB
• All other associated electrical components and electronics should have a CE certificate.
• A fully operational ant dust system.
• The conveyor made of a unique AISI 304 material.
• Well recognized manufacturing company for the Human Machine Interface(HMI) together with control panel.
• All the entire parts that come into contact with the products should be of SS AISI 316 and FDA compliant.

Some machines may lack some certifications due to your region and area of manufacture.

However, to be sure, please contact your local standardizing body to inquire about the different certifications available.

By being in touch with them will help you avoid substandard and counterfeit machinery.

Most importantly, go through the machine’s catalog to discover the standardization techniques for the specific equipment.

Types of Tablet Counting and Filling Machine

Of course, you will realize that different variety of tablet counting and filling machines are available.

Knowing all these types is essential for every user not only as a conventional way but also from a technical point of view.

As a result, I will take you through all of them.

Broadly, we can classify this equipment on two bases:

• Operational mode
• Range of model types

What’s the difference?

Let’s dig into that.

· Operational Mode

Well, with the rapidly development pharma technology, we have different types of counting and filling machines.

All of them are classified in accordance with their techniques of operation.

It thus implies, that under the operational mode, we can group them into:

• Fully Automatic
• Semi-automatic
• Manual

The significant difference between the two lies in the kind of technology in use by them.

Let’s put that clear.

a) Entirely Automatic Tablet Counting and Filling Machine

Honestly, fully automatic tablet counting and filling machine is continuously taking over the pharmaceutical industry by storm.

Fully Automatic Tablet Counting and Filling Machine

Indeed, identifying this class of equipment is very straightforward.

You only need to concentrate on the entire way it works.

Just as its name suggests, this equipment is entirely automatic.

Meaning, all its operations occur selflessly without any unnecessary human intervention.

This class of machine offers a technological and technical solution.

Why?

Counting and filling occur through the use of a special algorithm.

It has been made possible by interdisciplinary knowledge from the sectors of electronics, optics, computer engineering, and mechanics.

The purpose of borrowing this broad scope of knowledge is to achieve an excellent counting technique.

Though all these doesn’t mean that it eliminates human input, well, you have to make minor but critical contributions such as data entry and setting parameters.

That’s it; the rest of the operations will be done independently by the machine.

Consequently, you save a lot of time when dealing with this kind of device.

How?

You can perform other activities as the counting and filling process occur.

So, what are the salient features of fully automatic counters and fillers?

• It uses advanced high-tech image processing that enhances extremely accurate counting of tablets even in bulk quantities. The precision variation is less than 1%.
• This kind of sophisticated real-time image processing technology only utilizes a single large track. It’s in these tracks that the tech picks several counts of tablets and capsules at a go. Therefore, the device performs a bulk counting capability.
• It is super-fast in counting and filling tablets and capsules. The speed ranges up to 1000 tablets per minute.
• It’s fully computerized and uses a highly efficient programmable Logic control (PLC) for the entire operation.
• The human module Interface is a color touch screen panel from where the operator follows all the processes. Also, the screen enables the operation to move smoothly and more comfortably.
• Most of them have got a ‘No bottle, No count, No fill’ interlock system. So, therefore, no chances of wastage occur during the operation.
• The filling technology is super and fully comprehends the operation.
• The tablet counter has an automatic function of removing bottles which have got inappropriate filling levels together with irregular tablets.
• An effective anti-dust system that comes in hand when operating in a dusty environment.

We shall comprehensively discuss more details about the operational basis of this equipment later on.

· Semi-automatic Tablet Counting and Filling the Machine

Unlike the fully automatic one, this machine uses a semi-automatic transmission mode.

Implying that it makes use of both manual transmission and automatic transmission.

Naturally, the operational basis streams down into those functions that require human interventions to perform while others would intermittently occur within the equipment.

Semi-automatic Tablet Counting and Filling Machine – Photo Courtesy: Anchor Mark

So generally, human intervention would be occasionally needed when operating.

Now, this is also a very suitable machine for use and will give you that kind of result you will desire.

With that, let’s focus on some of the unique features of the semi-automatic tablet counting and filling machine.

• It has got a PLC system together with a suitable Human module interface (HMI)
• An infeed glass rotary table for automatic supply of bottles.
• It features a photoelectric system of scanners to accurately count the tablets and capsules.
• A superior filling accuracy.
• The device has an automatic infeed and discharge of bottles.
• Limited product change over intervals.
• All the machine contact parts with the products are AISI SS 316 material. The other parts construction is of AISI SS 304 material.
• It’s compact and of cGMP compliant certification.
• Equipped with “A no- bottle, no filing” system.

From these features, you realize that this is equally appropriate equipment for counting and filling your pharmaceutical products.

The unique features between the fully automatic and semi-automatic counters and filler machines seem the same. That’s right.

The difference between the two is indeed very little and that as well come down to the capabilities of the two classes of the machinery.

Now, which is the better equipment between the two?

That is an interesting question that most people grapple to answer.

But first, let’s have a look at significant distinct differences.

• Production rate – The fully automatic counter processes large quantities of pharmaceutical products in short duration compared to the semi-automatic one.
• Labour costs – the fully automatic machine is minimally dependent on supervision while the semi-automatic one somewhat depends on monitoring.
• Accuracy – the kind of sophisticated technology in use in the Fully automatic machine makes it extremely accurate almost 100% as compared to semi-automatic one.
• Initial costs – overall, the semi-automatic machine relatively costs less compared to a piece of fully automatic machinery.

From the above points, it’s clear enough that fully automatic tablet counting and the filling machine has the upper hand to the semi-automatic equipment.

But look, the choice between the two classes entirely lies upon your industrial demands.

So we can’t rule out the semi-automatic counter and filler.

In a nutshell, it’s paramount you choose equipment solely depending on your production needs and importantly the budget.

· Manual Tablet Counting and Filling the machine

Manual tablet counters and fillers are the pioneers in the market made of the old generation technology.

Consequently, it’s another set of machinery that complies to the CGMP standards.

With this machine, you can as well use different types and sizes of tablets, capsules, etc.

However, distinctively, this kind of majorly lies in the services of an operator.

There are straightforward ones which include handheld devices that are good for manually counting tablets.

Of course, the size mostly depends on the quantity you want to count.

Some are highly technical and do look exactly like the semi-automatic counters and fillers.

Some typical features of this machine are:

• Simple to operate – a professional supervisor would find it easy to operate including cleaning and changing of the parts.
• Vibration and multi-channel feeder to complement the processes.
• Most of them have got a dual channel filling capability that increases the rates of filling bottles.
• Its operation is dependable and works effortlessly with very minimal noise.
• The accuracy of counting is pretty good.

That’s all how we can classify the tablet counters and fillers depending on the operational technique.

It’s time to move into the next mode of classification.

· Range of Model Types

Based on the kinds of models available in the market, we can classify this machinery according to the number of counting channels.

Tablet Counting and Filling Machine

As such most of them are of multi-channel. Such as:

• Eight channel
• 12 channel
• 16 channel
• 24 channel
• 32 channel etc.

These two classifications are essential when grading the equipment.

Nevertheless, there could be still other available options.

Be sure to talk to a reliable manufacturer before making a purchase.

Why don’t we proceed to another significant segment of our discussion?

Parts of the Tablet Counting and Filling Machine

A tablet counting and filling machine is a mono unit that comprises of several components coordinating together to perform accurate counting and optimum filling.

Above all, all these systems integrate to avail the right productions.

The counter has several parts that potentially vary from a single machine to another.

For the basis of our discussion, we shall focus on the integral sections.

These essential parts are responsible for ensuring an excellent counting and filling process.

Below is a list of the parts:

a. Vibrating feeder

b. Counting system

c. Bottle feeding system

d. Cabinet

e. Control system

Complete Counting, Filling, Capping, Labeling, and Cartoning Line

Note that each of these parts has got distinct and integral functions in the counting and filling procedure.

Besides, you will realize the positions of all these segments may vary depending on the machine.

Interestingly, other tablet counters and fillers have got more segments compared to some.

Why so?
Every manufacturer may tweak his machine to suit a particular customers demand.

Besides, it could be a channel of uniquely presenting the product in the market to raise the clients to urge to purchase.

The bottom line is, always engage the manufacturer to provide you with the machine manual to be sure of the exact location of each part.

Why don’t we delve into details their respective roles?

· Vibrating Feeder

Vibrating feeder is a large segment that comprises of:

i. Tablet hopper

The hopper is the point where you load the tablets that you need to count.

Also, you can temporarily store a container full of pills as you wait for their turn for counting.

At the rear end of the tablet hopper, there is an alterable baffle.

It’s vital in case you’re dealing with large volumes of tablets or even prominent irregular shaped ones then.

The only thing you need to do is to attune to enable your tablets exit.

For hygiene purposes, you can easily take off the hopper to clean it.

ii. Vibrator

Depending on the machine you’re using, they all have got different grades of vibrations.

Take for example a 3-grade vibration.

It comprises of the first vibrator which is a long corrugated board.

A second vibrator that is a short corrugated board and finally a third one which is as well a flat board that is next to the hopper.

It’s possible to adjust the vibrations of the first and second vibrator by altering the parameters from the setting page.

For the third vibrator, you can alter the vibration by using a knob beside the control box.

The degree of vibrations is essential for regulating the flow of tablets.

Bottle Feeding Track – Photo courtesy: Medical Expo

iii. Tablet feeding track

Again, the feeding trucks vary also. For each machine, there is a separate number of channels.

These are multichannel that exist in 2, 4,8, 16, etc.

During the operation, the dust particles would collect into a dust collector due to the vibration.

Usually, the collector is at the fore section of the track.

As a result, you got to clean the collector regularly.

iv. Dust cap system

The material of the dust cap is Perspex.

The cap inhibits dust particles from spilling out which may bar your view and general monitoring of the ongoing feeding process.

Let’s now get into the fundamental point of the function of the machine.

· Counting System

The machine has got a system of droppers and track conveyors.

This counting scheme consists of a tablet guide plate, dropper, and counting heads.

Tablet Counting System – Photo Courtesy: Direct Industry

i. The Guide Plate

The plate directs the tablets into the counting chamber.

In most cases, the manufacturers customize it to suit the kinds of pills the user specializes.

ii. Dropper

The droppers can vary in numbers; some equipment has got multi-filling droppers while others have got a single one.

The droppers precisely fill the bottles with tablets once they get counted.

The diameter of the dropper has to match that of the mouth of the bottle.

As you deem it fit, you can adjust the position of the dropper using a screw that’s on the tip of the bottle mouth.

iii. Counting Heads

The counting heads are very vital especially to complement their functions; they have got fitting extremely responsive sensors.

The sensors automatically detect and count the tablets as they pass and concurrently transmit the signal information for display onto the control screen.

After that, you can effectively monitor the operations from the control system.

· Bottle Feeding System

The bottle feeding system is also another big section of the machine that comprises several units.

Definitely, for most machines, the bottle feeding system is always beneath the tablet dropper.

Some of The units which make up this system include the transmission section, conveyor belt, bottle hold bar, etc.

Bottle-Feeding System – Photo Courtesy: IMA

We should now discuss these segments.

i. Transmission section

It is a first section of the machine that’s responsible for giving the tool an adequate thrust to run the whole system.

It’s at this point that there is the transmission shaft.

This shaft generates the power for driving the motor.

ii. Conveyor

This conveyor comprises entirely of a chain belt that connects to the tension pulley at both ends of the conveyor.

Meaning, at the beginning and end of the conveyor there is a pulley.

So what does the conveyor do?

The conveyor facilitates the intake of the bottles in the right direction and at an appropriate speed.

To enhance the role of the conveyor, manufacturers do fix a partition panel in the center of the chain belt.

The panel divides the conveyor into a multi-number of sections that makes it possible to deliver an equal amount of bottles concurrently.

iii. Bottle Hold Bar

The bottle hold bars are the clips with a specific diameter but with an equal measurement to that of the bottle.

The clips attach themselves onto the bottle mouth to enable the feeding process.

To make it even more customizable, you can smoothly adjust the spacing in between the railings that are on the conveyor by the diameters of the bottles.

So that the measure of the distance between the bottles holds 1 and the next bottle hold 2 is equal to the diameter of the container.

Whenever all the bottles in the conveyor are filled up and discharged, the system ignites an alarm that would, in turn, send signals to stop the vibrator automatically.

That complex coordination is possible due to the operation of the inspection sensors.

These sensors are always at the top of the bottle holder, and they continuously monitor all the procedures thereby transmitting necessary signal information.

· Machine Cabinet

Working with industrial machines can sometimes be tiresome and demanding.

Occasionally, you will have to perform some mechanical procedure.

For that matter, the cabinet is one of the parts that you might need to consider altering.

Electrical Cabinet

The cabinet always consists of a cabinet casing, screws on pillars, adjustable pillars, etc.

Look, when installing the tablet counter and filler, it’s always paramount to set the machine to a suitable height.

Of course, a height that corresponds and links well with the other add-on tools or equipment.

To make the height adjustment then you need to go ahead and adjust the four mounting screws which are on the pillars.

· Control system

The control system comprises of all the electrical devices and electronics that aid in running the machine.

Most of these control devices will always be in the cabinet or the control box.

Automatic and semi-automatic machines make use of a PLC together with a suitable HMI.

Touch Control Panel

Finally, you can regulate the power through the power supply knob located on either side of the cabinet.

Aside from these primary sections, it’s worth noting that you can use the tablet counter and filler together with other add on devices.

Some of them include:

• A comprehensive Validation System
• Reinforced glass safety cabinet for your machine
• An audit trail facility

That’s it.

It’s very evident now that each segment plays a vital and specific role.

Furthermore, these parts work dependently to produce the best counting and filling results.

Currently, our next discussion would largely depend upon the functions of each component.

The good news is that you already know their contributions in the entire process.

Right?

Let’s have a look at how a Tablet counting and filling machine work.

Working Principles Of the Tablet Counting and Filling Machine

Remember, every other day manufacturers modify different tablet counters and fillers parameters.

However, one thing still stands; the working principle remains unchanged.

Why so?

The primary function done would always be merely counting and filling.

It, therefore, implies that the upcoming specifications only compliments the existing capabilities.

We shall look at the working principle in a while; however, let’s focus on this.

Quickly, how do you prepare the machine before even turning it on?

Preparation is an essential concept that most people tend to forget or even do rushingly without proper follow up.

Have a look at these tips to make you handle it.

• First, inspect the machine confirming whether all the connections are correct.
• Confirm if the tablet feeding and counting tracks are all in line.
• Make sure the power supply is adequate to run the machine. Look at the user manual to be sure of the exact power amount.

Let’s bounce back to the operation of the counter.

How Tablet Counters and Fillers Operate?

1. Feeding the tablets – Take your batch of pills that you need to count and place them on the hopper.
2. At this stage, you need to make some adjustments.

• Adjust the space between the hopper end and the last vibrator, i.e. flat board. You do this depending on the size of your tablets.
• Adjust the conveyor railing and the dropper height according to the bottle diameter together with the height.
• After that, adjust the trailing space. Start by loosening the fixed screw on the bottle feeder. Increase the distance that’s between the two railings on the conveyor preferably approximately 2mm more than the bottle diameter. Eventually, firmly fix the railing.
• Now alter the height of the dropper so that it’s 2mm higher than the bottle height. Use the control knob to do these changes. Usually, the knobs are “Up” and “Down.”
• Finally, tweak the bottle holding bar and ensure that the dropper has a proper fix on top of the bottles.

3. The vibration should initiate, and tablets vibrate within the rotating glass disc. Remember that every single disc is capable of counting coated and uncoated tablets, hard/soft capsules.
4. The delivery chutes after that direct the tablets from the counting disc into the filling tubes with varied sizes to fit into different containers.

The tablets pass through an infra-red beam as they drop.

These photoelectric sensors count the pills while they fall.

Note that you can preset all these operations of counting, several batches through the PLC and the information should be promptly on display on the HMI.

From this display, you can now monitor the operations.

5. Interconnected with a filler just beneath the hopper is a unique dust collector system. The collector enhances a dustless packaging of tablets into the containers.

The extraction makes it easy for capsule counting and pill counting.

Working with counting equipment is way much more comfortable and straightforward.

Please note

In case you’re working with an automatic machine, you don’t have to worry about the several adjustments we discussed above.

A state of the art equipment does most of the operations selflessly by use of the sophisticated PLC software.

The programming does all the counting, monitoring and filling procedures.

Therefore, you can control the entire process via the user interface.

Tablet Counting Filling Machine – Photo courtesy: Linear Filling Machine

Aside, there’re some few issues that you must pay close attention to during the operation.

So what are the most two complicated matters that require urgent considerations?

• The speed and accuracy of the tablet feeding because that’s the potential for unlocking a precise counting operation.
• Always respond at once when the alarm sounds and halts all the ongoing processing. Promptly solve the problem and restart the operation.

The above issues introduce us to errors that you may come by during working time.

Don’t worry; I will take you through ways of troubleshooting the machine later on.

But first, do you realize that each day manufacturers strive to improve performances of their productions?

It only means that even the Tablet counter is not an exception.

For that reason, it’s only worth that you keep in touch with your manufacturer to get updated always.

Do you know that each machine has got its unique demands and features?

Like the operating voltage, floor space, speed, accuracy. Etc.

It’s time we look at the specifications of the Tablet counter.

Right?

Technical Specifications of Tablet Counting and Filling Machine

Have you been a victim of making the wrong choice of a machine that doesn’t meet your material servicing needs?

Well, you’re not alone. Most people make such mistakes.

Why?

Reasons are several, but the most commons could be: inaccurate knowledge of the specifications and failure to read the user catalogue or manual.

So what’s the solution?

Strive to be aware of the machines’ parameters.

The only way to know these vital aspects is to request and read the catalogue.

Take for example TM-100 Tabletop Twin-Channel Tablet/ Capsule Counting Machine.

Figure showing SaintyCo TM-100 Tabletop Twin-Channel Tablet/capsule counting machine specification.

Have a look at another one.

Figure showing SaintyCo TC-100 Tabletop Tablet/Capsule Counter specifications.

Here is a different one again.

Figure showing TC-16 Tablet and Capsule Counter specifications.

The tablet counters are numerous, so we shall only use those three models of machines as case examples.

It’s evident from their technical specifications that each model is distinct and unique in its way.

Again, their features vary accordingly.

Meaning, it will be a gross mistake to judge one machine based on the other.

To avoid such misjudgment, you need to always refer to the machine catalogue.

By doing so, you will not only be picking a great machine but also one that fits your applications.

Another important concept related to the machine is the future technologies that the Manufacturers strive to update.

Let me take you through it.

Future Technology in Tablet Counting and Filling Machine

Development in Pharma Technology is vital in solving the current problems we experience with the ready machines in the market.

Thanks to the manufacturers and designers, some of these costly issues have got solutions at the moment while others are due to get answers.

Bottle Feeding System

Below is a list of what the manufacturers tip us that are due for improvement.

• Increment in the number of channels – there is general favoritism towards adding more channels in the future machines. Currently, most equipment has got up to 32 channels.
• Adoption of a sophisticated sensor system – Few users in the recent past are continuously complaining about recurrent meager errors in counting. That’s why search for the top most intelligent sensor system is ongoing.

Specifically, increasing multiple numbers of sensor eyes to achieve a consistent 100% counting accuracy.

Currently, the photoelectric sensor is popular.

• Upcoming development of more than a three stage vibration for proper feeding of tablets or capsules. Besides, the vibrating lanes would be a perfect suit for several kinds of products.
• Optimization of the auto-rejection system. The rejector should automatically eject improperly filled containers from the conveyor track.

Besides, it needs to concurrently send signals to the machine for initiating a reset of the counts.

• Improving the number of the flow of bottle discharge from single or double releases to multi-bottle form.
• Adoption of dual dust extraction ports and even more together with a stable anti-dust sensor capable of dealing with the highly useful working environment. The innovation is as opposed to the conventional dust collection box.
• It is increasing the overall output of the tablet counter so that it can produce thousands of tablets within a minute.
• Overall unique hopper designing to eliminate any chances of product jamming.

That aside, it’s common that you may experience difficulties when counting and filling with this machine.

Whenever such problems occur, don’t despair. We shall quickly analyze potential challenges and solutions.

How to Troubleshoot Tablet Counting and Filling Machine

So far, you already know how the counter works and the different demands of the parts of the equipment.

I am sure everyone including you love how simple the tablet counter works.

Unfortunately, things aren’t always smooth; occasionally you will experience problems that would require urgent attention.

That’s why you ever need to keep the user manual close to you for reference.

Most of these issues will be available in the document.

Nevertheless, let’s discuss some of the significant obstacles and ways in which you can readily solve them:

Tablet Filling System – Photo Courtesy: Medical Expo

1. Tablet jamming

Usually, jamming is due to the high speed.

To avert this problem regulate the vibration of the vibrator and the feeding track.

2. The Bottle stand isn’t in line

It could be as a result of the inaccurate timing of the bottle.

For such, correct the data via the control panel.

Besides, it may be that the dropper isn’t in line with the bottle opening.

To avert this, change the dropper station.

Finally, there might be over spacing between the railings on the conveyor for which you will need to adjust the railing spacings.

3. Counting and filing errors

The errors would be due to incorrect counting and end time.

Navigate to the settle page and adjust the channels.

Also, change the photoelectric gate time ensuring the unit is in a millisecond.

In case you observe the first bottle moving faster than the second one then it’s time to decrease the time.

Otherwise, add time for the converse.

4. Tablets spilling out of the bottle

The spillage is as a result of the vast distance gap between the filler dropper mouth and the bottle mouth.

Ensure that the height of the filling dropper corresponds to the distance between filling the dropper and bottle mouth are less than the tablet /capsule diameter.

5. Bottle trips as it passes by the hold

Falling could be as a result of a delay in the opening of the bottle holder.

To correct this situation, alter the bottle pass time via the parameter setting page in the control panel.

6. Counting sensor system becomes faulty

The fault here is most likely from the accumulating dust on the sensor.

You need to clean and tidy the sensor.

Moreover, the sensitivity of the counting sensor could be compromised

To make it sensible again, turn the small adjusting knob that’s on the sensor circuit board till it starts working still.

7. Sounding of alarm

The machine can initiate alarm because of several reasons:

First due to no bottle. Supply the containers.

Secondly, you may be using white bottles that are producing a powerful light.

Change this by putting out the light.

Thirdly, the sensitivity of the sensor could be low from trappings of the dust.

Subsequently, clean the sensor of any dust particles.

In summary, those are some of the undisputable glitches you’re likely to experience with the tablet counter and filling machine.

The good news is that you’re now capable of dealing with them.

Please note that for cases of mechanical damages, you got to consult with your manufacturer or a technician.

We proceed to the user requirement specification which is also a must-have a document for you.

Shall we proceed?

Tablet Counting and Filling Machine User Requirement Specification (URS)

The URS is a technical document prepared by the manufacturers or technicians of relevant machinery.

The document covers a range of factors such as the design, inspection protocols for the machine, various applications of the device, testing, responsibilities, machine specifications, quality standardizations, etc.

Moreover, it includes other vital documents that you have to use together with the user manual.

And the URS is even more significant whenever you want to place quotations since it entails all the critical information about the equipment.

The bottom line is the URS is a necessary document for you.

Machine URS

Now, let’s briefly have a look at some essential aspects of the Tablet counter.

i. Approval

This segment entails various certifications and confirmations by a relevant specialist in the field of tablet counting and filling machine.

The approval involves reviews and confirmations by duly signing.

ii. Introduction

The introduction section covers the full design, manufacturers’ details, testing, inspection and practically applying the tablet counter to perform a task.

Apart from that, the major sections include purpose, scope, general descriptions, and validation plans.

Besides, there will be a list of supporting documents that shows due validation of the equipment for tablet/capsule counting.

Remember, all the validation plans and reports are subject to approval by professional bodies such as QA, production, and Engineering.

Some of the Validation approaches include:

• performance qualification Test plan
• operation Qualification Test Plan
• installation Qualification Plan

iii. Overview

This segment describes the overall trend of the working principle of the tablet counter.

The significant subsections of this chapter are the use, capacity of the machine, range of products etc.

iv. Machine specification

The technical specifications of the machine that’s comprehensively outlined here are subject to:

• Operations
• Utility requirements
• Main physical parameters
• Material of construction
• Cleaning and tidying
• Safety measures and precautions
• Maintenance and spare parts

v. Plans and Documents

The supplier should readily have a written proposal and Design qualification for which he must seek approval from the client.

Moreover, during the inspection visit, the supplier shall avail you with dual copies of these documents:

• Equipment operational compliance
• Equipment completeness and accordance with designs
• IQ and OQ protocol and report among other several documents.

Besides another host of manuals and drawings will be available.

They include installation manuals, operational manual, service manuals, drawings of P and I diagram, etc.

Finally, as the proofs of compliance to regulations, the manufacturer shall supply you with a host of certificates which may include: declaration of conformity, cleaning certificate, material certificates for all the metallic parts in contact with product, etc.

vi. Samples of Materials for Tests

It entails a collection of components that the supplier requires to conduct tests for his purposes.

vii. Responsibilities

Responsibility section clarifies responsibilities for each stakeholder involved in the tablet counting and filling machine.

These parties are the supplier and the OHCL.

The supplier bears the sole responsibilities of guaranteeing that all calculations, plans, and other documents certifying the set standards.

Besides, the supplier needs to certify that the equipment adheres to the required manufacturing standard practices and safety.

Another party is the OHCL who has got several responsibilities such as: shipping the equipment, clearing customs, unloading, temporary storage, civil work among others.

viii. Factory Acceptance Test

Factory tests involve several tests protocols conducted at the supplier premises in the view of OHCL representatives.

The tests involve inspections and acceptance trials before delivering the equipment to the buyer.

Generally, the test is a confirmation of adherence to preset specifications.

ix. Site Acceptance Test (SAT), commissioning, validation, and training of owner’s personal

This part outlines that the supplier is in charge of conducting a supervise Site Acceptance Test (SAT) at the location of installation of equipment while solving any emerging problems.

On top, the supplier undertakes the training of the operational personnel.

x. Documentation standard

This section of the URS primarily deals with the set adherence procedures for all the relevant documents in use such as plans, certificates, drawings, etc.

xi. Export Packaging, Delivery job, insurance and Protection

Under this segment, the supplier will be in charge of the costs of transport, insurance, taxes, and duties involved in the delivery of the equipment as agreed.

During that period that the device is in the custody of the supplier, he assumes the responsibility of protecting it.

xii. Glossary

URS is one of the essential documents you need.

Conclusion

For the entire period of our discussion, you realize that the Tablet Counting and filling machine is vital for your pharmaceutical product counting.

You realize that the tablet counters come in different models and types of course with varied specifications.

The working principle and operations are equally simple and easy.

Above all, you would have to make a bold step in purchasing such a machine.

Luckily, am sure you are entirely in control to make such decisions based on the facts in the guide.

That’s it.

For inquiries or free consultations on tablet counting and filling machines, feel free to contact us.