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Hard gelatin capsules encapsulation Equipment

In the pharmaceutical world, encapsulation refers to various techniques to enclose and protect the drug ingredients by forming the capsule shell. Encapsulation equipment changes depending on whether the manufacturer needs to produce a soft or hard gel capsule. For instance, encapsulation systems and machines for softgels control the entire process from start to finish because their shells are filled at the same time they are produced. On the other hand, the filling of hard gel capsules comes by separating the body from the cap, and after the filling operations, the two parts are sealed together again, forming the shell.

Encapsulation

The two-piece capsule is a visual shorthand for all types of medical remedies. Advances in technology have made the production of hard-gelatin capsules a convenient delivery method for drugs and other ingested substances. But the simple solution requires micrometric precision to be manufactured to the proper pharmaceutical standards.

Hard gelatin capsules

Use of liquid filled hard capsules is increasingly popular with today's pharmaceutical manufacturers.  Bioavailability and patient compliance are enhanced with drugs delivered in this form.  Production of these liquid filled capsules requires equipment that can handle a wide variety of liquids including lipids and waxes, and automatically produce consistent sealed capsules as well as efficiency and high machine up-time to ensure profitability.


<h2>Automatically fill and seal hard capsules with any pharmaceutical liquid</h2>
Fluidocap F40 is a fully automatic machine for filling hard pharmaceutical capsules with liquid an sealing them.  It is provided by ACGE-Associated Capsules a world leader in pharmaceutical machinery manufacturing. Traditionally liquid doses have been provided in soft gel-cap form and have presented drug makers with the common problems of high cost, wastage, cross contamination, migration of the drug into the capsule, and low bioavailability.

The Fluidocap range of machines address these issues by allowing the filling and sealing of hard capsules with liquid compounds rather that relying on soft gelcaps.  The hard capsules can be filled with a wide range of formulations including lipid-based products, high viscosity pastes, and wax type products. They are sealed with a gelatin band. The capsule filler for liquid is designed for high volume production use and can produce up to 40,000 capsules per hour. Combinations filling including pellets in liquid is also possible using special attachments.

Automatic capsule filler for liquid solutions

A recent important change in the industry is the trend toward providing liquid doses contained in hard capsules.  The right equipment is need to develop processes to fill hard capsules with the wide variety of liquids used by today's pharmaceutical producers.  Laboratory equipment that is capable of handling waxes and lipids, automatically sealing the capsules, and maintaining a tightly controlled process suitable for scaling to production levels will give pharmaceutical innovators an edge of the competition.


<h2>Fill and seal hard capsules with any pharmaceutical liquid</h2>
Fluidocap 1000 is a semi-automatic machine for filling hard pharmaceutical capsules with liquid an sealing them.  It is provided by ACGE-Associated Capsules a world leader in pharmaceutical machinery manufacturing.  Traditionally liquid doses have been provided in soft gel-cap form and have presented drug makers with the common problems of high cost, wastage, cross contamination, migration of the drug into the capsule, and low bioavailability.

The Fluidocap range of machines address these issues by allowing the filling and sealing of hard capsules with liquid compounds rather that relying on soft gelcaps.  The hard capsules can be filled with a wide range of formulations including lipid-based products, high viscosity pastes, and wax type products.  They are sealed with a gelatin band.  The Fluidocap 1000 capsule filler for liquid is designed for laboratory use and can produce up to 1000 capsules per hour but can easily be scaled up to commercial level production.

Laboratory capsule filler for liquid solutions

<span style="font-weight: 400;">For the production of pharmaceutical doses in capsule form complete accuracy of fill is paramount. To increase production efficiency and reduce costs this must be married effectively with high performance. This is a vital combination for lower volume production lines.</span>
<h2>High performance capsule filler for lower volume production line</h2>
<span style="font-weight: 400;">The Sejong Pharmatech F50 series is an entry-level capsule filling solution with cutting edge features that can enhance output by up to 26% and increase throughput speed by 12% compared to last generation machines, able to operate at 50,000 units per hour.</span>

<span style="font-weight: 400;">The F50’s index and cam drive power train also significantly reduces noise and vibration, increasing lifespan and reducing maintenance, and the whole unit is designed to allow for simple parts exchange where required. Advanced features include automatic capsule jam removal using high pressure air, without the requirement to disassemble the unit.</span>

<span style="font-weight: 400;">With a focus on accuracy, the F50 uses a 5 stage compression moulding system before filling to achieve the optimum results. Automatic weight control (AWC) function reduces fill variation to absolute minimum, and the system not only rejects capsules outside the variance limit, but also automatically reject any faulty capsule, for example due to imperfect closure or damaged capsule sleeve.</span>

<span style="font-weight: 400;">To suit your exact requirements, the F50 is able to handle a wide variety of dosages, including powders, pellets and tablets - allowing it to be used to fill combination capsules as well as single dose types.</span>

<span style="font-weight: 400;">The control system is fully 21CFR part 11 compliant, with graphical touchscreen control for ease of operation and monitoring of performance.</span>

Entry level capsule filler

<span style="font-weight: 400;">For higher production volumes of pharmaceutical capsules, speed, accuracy and reliability of production machinery is vital. For medium volume production lines this combination becomes particularly important, as increased speed should not detract from the highest levels of accuracy and efficiency.</span>
<h2>High performance capsule filler for medium volume production line</h2>
<span style="font-weight: 400;">The Sejong Pharmatech F125 series is a scale-up capsule filling solution with cutting edge features that can operate at up to 126,000 units per hour.</span>

<span style="font-weight: 400;">The F125 has an innovative drive train that has been designed to reduce vibration levels, this results in lower noise and a longer component lifespan. Modular construction means part replacement is straightforward and simple when required.</span>

<span style="font-weight: 400;">Advanced features include a high pressure air system for the automatic clearance of capsule jams. This reduces downtime as there is no need to disassemble the unit.</span>

<span style="font-weight: 400;">For the highest accuracy levels, the F125 uses a 5 stage compression molding system prior to fill. This ensures optimum pressing results. In addition, the automatic weight control system ensures minimal variance from the programmed fill level, and offers automatic rejection of failed fills, as well as imperfect capsule closures or damaged sleeves.</span>

<span style="font-weight: 400;">To suit your exact requirements, the F125 can produce a large variety of doses, filling capsules with powders, tablet and pellets. The F125 can also produce combination capsules containing mixed dosage types.The control system is fully 21CFR part 11 compliant, with graphical touchscreen control for ease of operation and monitoring of performance.</span>

Scale up capsule filler

<span style="font-weight: 400;">In the highest volume pharmaceutical production environments, capsule filling needs to be extremely accurate whilst providing increased throughput in order to improve efficiency. Equipment that is designed to minimize downtime becomes particularly important in larger-scale production.</span>
<h2>Highest performance capsule filler for large volume production line</h2>
<span style="font-weight: 400;">The Sejong Pharmatech F180 series is a high capacity capsule filling solution with cutting edge features that can operate at up to 184,000 units per hour.</span>

<span style="font-weight: 400;">The F180’s proprietary drive system has been designed to offer maximum speed and performance whilst minimizing maintenance through reduced vibration. In addition, the modular nature of the system allows for rapid and straightforward replacement of individual components, keeping downtime to a minimum.</span>

<span style="font-weight: 400;">Further innovation includes the provision of an automated capsule jam removal system. Using high pressure air, the machine can self-clear without the need for any disassembly, saving valuable time.</span>

<span style="font-weight: 400;">Because increased speed must not lead to a reduction in quality, the F180 is fitted with a 5 stage compression moulding system to ensure the optimum capsule fill even at highest speeds.</span>

<span style="font-weight: 400;">In addition, the comprehensive AWC (automatic weight control) functions reject any doses that are not filled within tolerance, as well as automatically rejected any faulty capsules that have not fully closed, or where the capsule sleeve has been damaged.</span>

<span style="font-weight: 400;">To meet your exact needs and offer full flexibility, the F180 is able to handle a wide variety of encapsulated dosage types, including powders, pellets and tablets. It can also fill capsules with a mixture of these doses, allowing scope for the production of a large number of products.</span>

<span style="font-weight: 400;">The control system is fully 21CFR part 11 compliant, with graphical touchscreen control for ease of operation and monitoring of performance.</span>

High capacity capsule filler

<span style="font-weight: 400;">The production of pharmaceutical capsules requires that individual doses are checked for accuracy. In a production environment this also needs to be done at speed. Fast throughput and ease of use are important in a production scale checkweigher.</span>
<h2>High accuracy, easy-to-use weight checkers for a range of production scales</h2>
<span style="font-weight: 400;">The Sejong Pharmatech iW Series of production weight checkers have been specifically designed to give the highest accuracy whilst maximising throughput and simplifying operation and maintenance.</span>

<span style="font-weight: 400;">Available in 4 variants, the iW series is capable of checking 10,000, 60,000, 120,000 or 180,000 units per hour to suit your exact requirements.</span>

<span style="font-weight: 400;">The highly accurate weight cell used offers accuracy of +/-2mg whilst operating at these speeds, and the simple to use touchscreen display provides instant graphical feedback on the performance of the unit. The control system is fully 21CFR part 11 compliant for record-keeping and monitoring.</span>

<span style="font-weight: 400;">Able to handle a range of capsule sizes from #000 to #5, the machine has two output paths, one for pass, one for reject. Optional extras include air conveyor to transport capsules from the pass chute to storage container.</span>

<span style="font-weight: 400;">The machines are top loaded for convenience and feature built-in castors to allow easy movement of location or to access parts of the machine for maintenance and inspection.</span>

Capsule checkweigher

<span style="font-weight: 400;">By employing a weight sorter that is fully flexible and able to handle a wide variety of dose shapes and sizes you can benefit from reduced equipment cost and improved production. Such flexibility without the requirement to change machine parts is now available for large scale production facilities.</span>
<h2>Easy to use, fully flexible weight sorter for large scale production</h2>
<span style="font-weight: 400;">The SADE SP440 from CI Precision is a highly accurate, easy to operate and fully flexible dosage weight sorter for use in larger-scale production environments. Featuring a single 150l hopper and 4 weighing channels for bulk operations at up to 22,000 units per hour and an easy-to-use operator interface, the SADE SP440 is accurate to within +/- 2mg.</span>

<span style="font-weight: 400;">Designed with flexibility in mind, the SADE SP440 can handle a wide range of tablets and capsules, switching between them with no requirement for changing physical parts to accommodate different dose types. The SADE is able to weigh tablets up to 20mm x 24mm, and capsules from 5 through to 00 size (larger sizes may be accommodated). The machine is also able to be quickly and easily dismantled for cleaning and sanitizing.</span>

<span style="font-weight: 400;">The unit has the ability to reclaim “good” product from a weight-rejected batch, saving valuable product and producing less waste. The unit records all sort operations and can print reports direct to a printer or send to a PC.</span>

High capacity weight sorter for tablets &amp; capsules

The billions of microbes living in our gut have a significant impact on gastrointestinal health, mood, and behavior. Every individual develops their microbiome community. Probiotic processing technology makes sure that harmful bacteria never outnumber good citizens.

Probiotics

Chewable tablets are suitable for patients who have difficulty swallowing. Chewable tablet formulation masks the natural flavors of pharma drugs and alters their aftertaste. But besides the taste, chewable tablets favor the bioavailability of pharmaceutical ingredients.

Chewable tablets

The fizz of effervescent tablets is commonly associated with a vitamin C boost. But the soluble pill is an excellent drug delivery method for pediatric and geriatric patients. Sometimes referred to as carbon tablets, manufacturing effervescent tablets binds biocarbonate and citric acid that produce the smooth hiss as they dissolve in liquid.

Effervescent tablets

When taking a tablet, it is usually the job of our stomach to break down the medication to make it ready to be absorbed into the bloodstream. However, some drugs are not meant to be dissolved in the stomach because the acidic pH of the stomach can disintegrate the drug, making it no longer effective. Using tablet coating equipment that applies a polymer barrier to the tablet makes it possible to protect it from stomach acidity.

Enteric Coated Tablets

Microtablets range between 1 and 4 millimeters, making the dosage form an excellent delivery system in polypharmacy. The size of the products makes them easier pills to swallow, but microtablets production brings a unique set of complexities.

Microtablets

Multilayer tablets are a popular fixed-dose combination (FDC) offering a range of release profiles for effective drug delivery. Multilayer tablet technology solves challenges to API consistency, allowing manufacturers to develop formulations from incompatible ingredients while optimizing the release profile for immediate release and controlled release.

Multi-layer tablets

Softgel capsules fast-track the delivery of medication to the bloodstream. Unlike solid pills, they do not need to be broken down by the body before the drugs can be absorbed. Moreover, they are optimal vehicles for oils and fat-soluble formulations that cannot be compressed into tablets.

Softgel capsules

The nonproprietary name for HPMC – hydroxypropyl methylcellulose – is such a mouthful that it has two abbreviations. Hypromellose is the other one. The non-ionized material offers a safe alternative to gelatin capsules, especially as most common API and excipients are suitable HPMC capsule ingredients.

HPMC capsules

Making.com is a new online platform that helps makers find production technology quicker by grouping it around the products they make.

What's new in pharmaceutical packaging?



During <a href="https://www.pharmapackeurope.com/en/home.html" target="_blank" rel="noopener">Pharmapack</a>, we met Chantal Younes, Key Account Manager at <a href="https://www.csptechnologies.com/" target="_blank" rel="noopener">Aptar CSP Technology</a>, who introduced us to the world of active packaging.

The pharmaceutical industry is subject to strict regulations, so that's why manufacturers are very meticulous when formulating their products but especially about their packaging, which must keep their products safe. Due to the formulation or active ingredient, pharmaceutical products can present significant stability issues if they come in contact with moisture or oxygen.

This is where Aptar CSP Technology comes in. Aptar CSP Technology has developed several active packaging solutions to protect pharmaceutical products and ensure extended shelf life.

The company has developed a new class of highly engineered polymer compounds that protect drug products, probiotics, and drug delivery systems from impurities, oxygen, and moisture. The polymer can be extruded into a film, injection molded, or blow molded.

#Changemaker: Ready to protect your pharmaceutical products from moisture?

Pharmaceutical

The most important part of a capsule is its contents. But if the shell is not carefully made, the dosage ingredients inside lose effectiveness. From molding to sizing, capsule manufacturing equipment forms perfectly-matching husks ready for filling. The simplicity of encapsulation revolutionized pharmaceuticals since it was introduced in the 19<sup>th</sup> century. However, capsules are changing to increase delivery efficiency and reduce the dependency on gelatin.

Capsules

Parenteral preparations refer to drugs using non-oral means of administration. Injectables, such as needles and syringes, are used to deliver a drug into the systemic circulation directly in the veins, muscles, under the skin, or in the tissue.

These parenteral formulations are pharmaceutical dosage forms that have strict regulations on being sterile, pyrogen-free, and free from visible particulate matter including reconstituted sterile powders. Solutions, suspensions, emulsions, and gels with APIs intended for administration by injection are usually supplied in vials, ampoules, pre-filled syringes, or pens to facilitate ease of use.

Injectables

<p class="filterable-grid__description">Liquid dosage forms are designed for easy absorption. The body quickly carries the active ingredients through the system and triggers the required response. But the greatest advantage of this medicinal type is its flexibility in formulation and dispensation. From lotions and syrups to drops and sprays, liquid solutions can be adapted to different administration routes including parenteral, topical, and oral. The fundamental liquid dosage manufacturing process involves dissolving or suspending solutes in a fluid. But that is not enough. A precise blend of excipients is needed to make the medicine go down.</p>

Liquid dosage forms

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

Among all dosage forms in use today, tablets constitute the most common one. They are pharmaceutical solid dosage forms containing active ingredients and excipients such as diluents, binders, glidants, and lubricants. Using tablet making equipment, these solid dosage forms are made by compression of granules or powder blends and then shaped by molding.

Tablets

Sensum specialises in the development and production of automatic visual inspection systems for the pharmaceutical and nutraceutical industry.

Thousands of different capsules are produced every day, so it is inevitable that some of them will come out <a href="https://www.sensum.eu/posts/reasons-for-most-common-capsule-defects/">defect</a> in shape or size, with a colour deviation, cracks, dents or maybe a missing print. However, a defective capsule in a package can lead to unpleasant consequences. A complaint or even loss of brand are the worst-case scenario for a manufacturer.  Reliable detection of defects depends on quality of inspection system, where 3 key aspects have to be considered: optical system, mechanical manipulation and image analysis.


<h2>Using different light modes to see various capsule defects</h2>
Have you ever tried taking a picture of someone with the sun on the background? The result will be a dark silhouette. This is not the best outcome, if you need well visible face, but could be a great picture if you are looking to hide it. Similarly, in industrial inspection, different light shows different defects. In capsule inspection, backlighting helps to analyze capsule’s shape and size. On the other hand, backlighting alone cannot see every anomaly, like color deviation. Each defect requires a different light mode. In short, diffuse light detects dirt, dots, and colour defects, while 3D surface imaging can spot defects such as dents and cuts on capsules and embossing, engraving or coating defects on <a href="https://making.com/products/tablets">pharmaceutical tablets</a>. Working together, the three different light modes can provide a better inspection and end-product quality.
<h2>How does mechanical manipulation impact visual inspection?</h2>
There are plenty visual inspection technologies with different manipulation. However, to be sure that defects are not overlooked by the system, proper mechanical manipulation is just as important as having different light modes in the optical system. For example, suboptimal <a href="https://making.com/products/capsules">capsule</a> movement during image acquisition can make images blurry. Aiming for a machine that has gentle and reliable mechanical manipulation (controlled movement of products) combined with different lighting modes, leads to better defect detection.

Last but not least, image analysis and inspection software need to allow reliable detection of defects on images, simple sensitivity setting for various measurements and quick setting of recipes for new products. Watch the video below to see how <a href="https://www.making.com/equipment/high-speed-visual-inspection-system-for-tablets/">Sensum Spine</a> is able to inspect up to 630.000 capsule per hour performing up to 18 images per product .

[embed]https://www.youtube.com/watch?v=viNPErB2BBs[/embed]

How reliable imaging plays an important role in capsule visual inspection

It is strange how two tablets can belong to the same but at the same time to a different category depending on how the tablet itself is classified. For example, chewable tablets and effervescent tablets have two different routes of administration but both belong to the category of uncoated tablets. Uncoated tablets are prepared by compression of granules in which no coating is added after compression. They may be single-layer or multi-layer tablets.

Uncoated tablets

Did I take my medicine this morning or not?

Let's be honest. How often have we asked ourselves this question and failed to find an answer simply because… our memory sometimes doesn’t serve us right!

&nbsp;

Coming to the rescue of patients who need to keep track of their chronic medication and adhere to their daily treatment plan is FebriSol, a scratch-card calendar developed by Studio Fundi.

At <a href="https://www.pharmapackeurope.com/en/home.html" target="_blank" rel="noopener">Pharmapack</a>, we had the pleasure of meeting Ricky Stoch, the founder of <a href="https://studiofundi.com/" target="_blank" rel="noopener">Studio Fundi</a>, who showed us how simple it is to use FebriSol.

All the patient has to do is scratch off the day’s metallic coating that will reveal the check mark after taking the pill.

Current solutions for daily tracking are inconvenient and expensive.  FebriSol is a low-cost alternative that can help you keep track of your medicine every day.

#Changemaker: Keep track of your medicine every day with FabriSol sticker

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Hard gelatin capsules encapsulation Equipment

Which hard gelatin capsules encapsulation technology do you need?

Automatic capsule filler for liquid solutions

Laboratory capsule filler for liquid solutions

Entry level capsule filler

Scale up capsule filler

High capacity capsule filler

Capsule checkweigher

High capacity weight sorter for tablets & capsules

There is currently no equipment listed with your specified properties, but we are sure we can help you. Try us!Contact us

Let's talk about your project!

Which hard gelatin capsules encapsulation technology do you need?

Automatic capsule filler for liquid solutions

Laboratory capsule filler for liquid solutions

Entry level capsule filler

Scale up capsule filler

High capacity capsule filler

Capsule checkweigher

High capacity weight sorter for tablets &amp; capsules

There is currently no equipment listed with your specified properties, but we are sure we can help you. Try us!Contact us

Let's talk about your project!

High capacity weight sorter for tablets & capsules