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Hard gelatin capsules filling Equipment

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

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

Automatic capsule filling machine for powders, pellets, tablets, mini-tablets, capsule in capsule or liquids.


<h2>Test the automatic settings of your capsuling process before you scale-up</h2>
IN-CAP automatic bench top capsule filling machine by Dott.Bonapace is a bench top automatic capsule filler. It has become popular all over the world among R&amp;D laboratories, pharmacies, hospitals, etc. For trials research, batch productions, and in laboratories for full production utilization. It is also available with predisposal of liquids or semi-dense products filling station, pellets, tablets and mini-tablets. The machine can be supplied either with tamping or dosator system. Machine manufactured according to CE and GMP rules.

R&D automatic capsule filler

Semi-automatic filling machine suitable to open, fill and close empty hard gelatin capsules already orientated on a 300 holes tray, with an hourly output of approximately 6000 capsules.


<h2>Semi-automatic capsule processing machine</h2>
The KAP, R&amp;D semi-automatic capsule filler, by Dott. Bonapace is available in two configurations:

KAP-300: The KAP-300 is suitable to open, fill and close empty hard gelatin capsules already orientated on a 300 holes tray. To ensure the correct and easy distribution of the powder into the capsules, the machine is equipped with an electronic vibrator. It has an hourly rate up of 6000 capsules.

KAP-100: The smallest solution: Two units in one only basement with electrical parts in stainless box 100% at water tight. It is ideal for hospitals, pharmacies, research laboratories and quality control departments where small production batches are required. It has an hourly output of 2500 capsules.

R&D semi-automatic capsule filler

A semi-automatic orienter for capsules with an output speed up to 6000 capsules.


<h2>Orientate your capsules so that they are ready for filling</h2>
The RK-15 capsule filler by Dott. Bonapace  is an R&amp;D capsule orientater which processes 150 capsules per cycle; by repeating the operation also 300 capsules can be processed. In the version of 150 capsules per tray, the RK-15 can work with the filling unit KAP-150 and KAP-300.

Hourly output: up to 4000 capsules in combination with KAP-150, Up to 6000 capsules in combination with KAP-150.

R&D capsule orientater

Staying competitive in today's highly dynamic and highly regulated pharmaceutical production market requires encapsulation equipment with the utmost process control and batch documentation.  Quick changeover, and accurate dose control are required as well as enhanced features like environmental sensors, online weight adjustment and automated documentation and reporting.  Successful modern producers use these next-generation features to maintain an edge of competitors with more traditional equipment.


<h2>A complete automatic encapsulation solution with state-of-the-art accuracy controls and reporting functionality.</h2>
The Legend 2500 from ACG-PAM is a fully automatic capsule filler with next generation design which greatly enhances production speed and efficiency.  ACG-Pam has over three decades of experience in the pharmaceutical manufacturing industry and the success of the company's AF series of encapsulating machines which are installed in over 1,000 facilities across the globe provides a knowledge base and industry expertise that is second to none.  The Legend 2500 encapsulation represents the application of this knowledge and experience specifically to improve upon existing encapsulation systems and better meet the needs of today's pharmaceutical producers.

The system includes Industrial PC based controls, online weight adjustment, and a screw type auger for use with the widest variety of formulations.  The need for an extra doing disc when filling doses are 50% of slug length is eliminated by use of a slug length adjustment kit.  Anti-jamming features for trouble free capsule loading and automatic lubrication are also included.  The system makes use of integrated environmental sensors, a stand-alone security enabled IPC control pedestal, and full 21 CFR Part 11 compliant reporting to ensure an encapsulation process that is accurate, controlled, and well documented.

Easy to validate capsule filler

Pharmaceutical manufacturers require maximum yield from their encapsulation process for efficient production and competitive results.  Leaving expensive pharmaceutical formulations in the encapsulation machine as left-over or dust is wasteful and inefficient.  Equipment with all the features required for accurate high quality encapsulation as well as enhancements for minimized dust creation and product loss will give users a distinct advantage over the competition.


<h2>A complete encapsulation solution for maximum yield</h2>
The ZRO 90T system from ACGE is a production scale capsule filler from the AF series of capsule fillers that is currently running in over 1,000 production facilities throughout the world.  The AF series of machines is built for regulatory compliance, revenue optimization, and flexibility giving pharmaceutical manufacturers the features they demand such as formulation and dosing control, minimal product loss, a wide range of peripheral equipment, and globally available support.

The ZRO 90T machine has all the benefits associated with the series as well as additional features to minimize formulation loss during processing and maximizing yield.  The capsule filler includes ACGE's patented ZRO technology which minimizes dusting and separation by containing the formulation within the dosing disk.  This technology reduces formulation waste and maximizes powder use efficiency for maximum yield.

High-yield capsule filler

Capsule filling should be a worry-step in pharmaceutical and nutraceutical manufacturing.  The right equipment is capable of fully automatic operation, includes accurate dose control, is easily changed over between products, and includes supporting accessories for smooth integration with other processes.  A high quality capsule filler will give plant managers peace of mind and allow them to focus on improving other aspects of their operation.


<h2>A complete, automatic encapsulation solution</h2>
The AF series from ACG-Pam is a production scale capsule filler line that is currently running in over 1000 production facilities throughout the world.  The AF series of machines is built for regulatory compliance, revenue optimization, and flexibility giving pharmaceutical manufacturers the features they demand such as formulation and dosing control, minimal product loss, a wide range of peripheral equipment, and globally available support.

The automatic capsule fillers can output from 6,000 to 200,000 capsules per hour and can handle powder, microtablet, and pellet, and capsule-in-capsule filling.  They include ACG-Pam's patented ZRO technology which reduces dusting and product loss during operation as well as other features designed for revenue optimization and machine efficiency.  The AF series machines in production have handled over 3,000 different formulations and ACG-Pam's support personnel have developed the expertise and knowledge based needed to tailor an encapsulation solution for even the most difficult formulations.

Automatic capsule filler

For pharmaceutical formulations that are highly active specialized capsule filling equipment is often required for operator safety and protection of product quality.  Full containment in a capsule filling process requires, minimal creation of dust, minimized product left-over in the machine, and operation with minimal operator interaction.  This specialized equipment offers these enhanced features including glove box operator access as well as all other capabilities expected from a top-of-the line pharmaceutical capsule filler.


<h2>Contained, safe encapsulation for highly active formulations.</h2>
The Securefill 12T from ACGE is a fully automatic  high containment encapsulation solution for highly active substances. The contained capsule filler is specifically designed to prevent any surface or airborne contamination escaping the machine which can be a risk to operator safety when working with highly active pharmaceutical formulations.  Contact between the operator and the formulation is eliminated greatly reducing the complexity and unreliability of other protective methods commonly used.

Part of the AF series of encapsulation machines which are currently running over 1,000 pharmaceutical production facilities world wide, the Securefill 12T has all the proven design benefits and flexibility of the other machines, with added containment and operator protection features.  Capacity of the contained capsule filler is up to 12,000 capsules per hour.

Contained capsule filler

Innovators in the highly regulated and highly dynamic pharmaceutical market place need equipment that is worry-free and flexible enough to vary products and process variables as new products are developed.  Laboratory capsule filling machine must be easy to maintain, allow for rapid tooling change-over, and provide tightly controlled process variables and automatic operation in order to ensure results that are reproducible at the production scale.


<h2>A complete encapsulation solution for the laboratory</h2>
The AFT-T Lab system from ACGE is a laboratory capsule filler from the AF series of capsule fillers that is currently running in over 1000 production facilities throughout the world.  The AF series of machines is built for regulatory compliance, revenue optimization, and flexibility giving pharmaceutical manufacturers the features they demand such as formulation and dosing control, minimal product loss, a wide range of peripheral equipment, and globally available support.

The AFT-T Lab machine has all the benefits associated with the larger equipment in the series but on a scale appropriate for laboratories.  The machine can output up to 6,000 capsules per hour for powder filling and 5,000 capsules per hour for pellet filling.  It uses a 1.1 kW primary motor.  It weighs about 1,200 Kg and occupies only 2.25 square meters of floor space making it the perfect scale for any pharmaceutical laboratory.

Automatic laboratory capsule filler

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

Hard gelatin capsules are a popular format for delivering a wide variety of pharmaceutical doses. For small batch production, a semi-automatic capsule filling solution delivers tangible benefits in terms of increased efficiency, accuracy, and throughput, particularly when combined with a complimentary capsule loading system.
<h2>Capsule filler for hard gel capsules</h2>
The MS 6 AUT Capsule Filler from Multigel is a semi-automatic solution designed to be used alongside the MS 1 capsule loader.

MS 6 AUT is capable of filling and closing up to 300 capsules per batch and is flexible enough to fill a range of sizes from 000 up to 5.

To facilitate accurate dosing, the MS 6 AUT is fitted with a vibrating plate with intensity adjustment that ensures optimum filling of fine as well as coarser powder compounds.

The powder packing unit further assists in ensuring a smooth and even descent of powder into all the capsules, reducing the time taken to achieve a correct fill.

All parts of the machine that come into contact with powders are quickly and easily removed allowing for speedy and thorough cleaning when required to minimise downtime.

&nbsp;

Semi-automatic capsule filler

For medium-scale production of solid doses such as tablets, capsules, and softgels that are provided in standard counts, an automated counting and filling line will increase your efficiency. Used in pharmaceutical and nutraceutical production, such a fully automated line will enable you to upscale your production easily. At the same time, it will reduce the overheads involved with running semi-automatic or manual filling alternatives that offer slower throughput.
<h2>Complete automatic solution for solid dose counting and bottles filling</h2>
The ACL 1500 from Multigel is a fully automated solution for accurately counting solid doses, such us tablets, soft gels and hard capsules and then automatically filling them into appropriate containers. It can process sizes from 5mm to 25mm diameter and up to 20mm thickness.

The unit comprises a CPE 6 automatic counting machine linked to a rotating stainless table for automatic bottle feeding. Bottles then run on a conveyor to the doser. Following filling, they pass to a bottle collection unit or optionally output into other machinery such as closing, labelling and inspection units.

The unit can process up to 200,000 doses per hour, requiring only a single operator to keep the bottle feeder and dose hoppers stocked. The machine features a touchscreen interface to set and monitor all parameters.

Optional extras include a 3-point dedusting device for tablet dosing, reducing downtime associated with sensor cleaning.

All product contact areas are made from 316 stainless or FDA-approved material and feature easy access for cleaning.

Automatic filling line for solid doses

Medicines in tablet, capsule, or soft gel forms undergo various processes before reaching the consumer. Of the steps involved in production and packaging, automatic visual inspection and accurate counting with filling are essential to meet quality standards and specifications. Since separate equipment for each process step adds high costs, multi-function machines are much better in this regard.
<h2>Automatic Inspection and Bottle Filling of Capsules, Tablets, and Soft Gels</h2>
Spine Fibo by Sensum is designed to ensure accurate automatic visual inspection, sorting, counting, and filling of tablets, capsules, and soft gels. Products are conveyed through an optical system, which can perform a 100 percent visual inspection of each product using several cameras. During the inspection, products are counted for the first time. After inspection, defective products are rejected, while only good products are counted again with an additional optical system and then filled into bottles. Another advantageous feature of Spine Fibo is that it uses no flaps at bottle filling. With such double counting and no-flap system, the machine ensures high accuracy in counting and reduces risks of defective products getting to the market.

Spine Fibo can handle smaller and bigger bottles, and no formatting of parts is required for bottle changing. It can identify many defects like foreign products, size variations, thickness variations, lamination, engraving defects, coating problems, chips, cracks, dots, dents, bubbles, variations in prints, and texture. This equipment can inspect pharmaceutical products like plain, coated, and multi-layer tablets, opaque, bi-color, transparent capsules, and a large variety of soft gels. In addition, defective samples are not required to train the system.

High speed bottle filler with inspection

In R&D or pilot-scale production, ensuring the integrity of liquid-filled capsules is critical. Challenges include precise dosing, effective sealing, and maintaining the stability of various formulations, such as hot melts and pastes, during production.
<h2>Fill, close, and seal liquid capsules efficiently</h2>
The FLUIDOCAP 1000 from ACG World is a semi-automatic solution designed for filling hard capsules with liquids, integrating closing and band-sealing processes into a single, compact unit. It accommodates a variety of capsule sizes, ranging from 00 to 4, in both gelatine and vegetarian variants. The system handles formulations with viscosities from 40 to 3,000 cP, ensuring reliable filling of pastes, hot melts, and thixotropic solutions. Its band-sealing and drying capabilities enhance the dosage form's integrity and shelf life. With a maximum speed of 1,000 capsules per hour, it is ideal for R&D labs or small-scale production environments seeking efficient and precise liquid capsule filling.

Liquid capsule filling for r&d and pilot-scale production

In pharmaceutical and nutraceutical manufacturing, achieving high yields and efficient filling of capsules, particularly with powders difficult to tamp or compact, can be challenging. Large-volume production demands equipment that minimizes powder waste and maximizes productivity.
<h2>Ensures high-speed, dust-free capsule filling</h2>
The ZRO 200T by ACG World is a high-performance capsule filler designed to handle large batches efficiently. With a capacity of up to 200,000 capsules per hour, it is ideal for pharmaceutical and nutraceutical industries where high-volume production is crucial. The patented ZRO technology in the powder-filling station ensures minimal powder wastage and high capsule yields, even with sticky, fluffy, hygroscopic, and heat-sensitive powders. The machine supports partial filling capabilities, accommodating capsule sizes from 000 to 5, making it versatile for various product formulations. Notably, it can fill not only powders but also pellets, tablets, micro-tablets, capsules, soft gels, and combinations thereof. Integration with ACG's ACCURA 100% capsule check-weigher guarantees precise capsule weight, and mechanical changeover can be completed in under an hour, ensuring minimal downtime and maximum productivity.

High-speed capsule filler for large batch production

When producing pharmaceutical or nutraceutical capsules, achieving consistent fill weights and maintaining a hygienic production environment are crucial. Manual methods often result in variable dose accuracy and increased contamination risk, necessitating a reliable filling method.
<h2>Fill capsules accurately and efficiently</h2>
The ProFiller 1100 by Adelphi is a benchtop semi-automatic capsule filler designed for small to medium batch sizes. The unit efficiently orients, separates, fills, and fully locks 100 capsules at a time, with a throughput of up to 3,400 capsules per hour. Its patented design enhances speed and filling accuracy, achieving fill weight precision within ± 1-2% using the USP/EP method. Constructed from 316L pharmaceutical-grade stainless steel, the ProFiller 1100 is fully dishwasher safe and easy to disassemble without tools. Compatible with capsule sizes ranging from 000 to 5 and all EL sizes, the unit also features a quick change part system and offers additional accessories such as powder vibrators for various powder types.

Capsule filling solution for small to medium batch sizes

In the pharmaceutical industry, ensuring precise dosing and minimizing waste are critical during capsule production. Addressing such requirements calls for equipment that can handle high output while maintaining accuracy and compliance with quality standards.
<h2>Orient, separate, fill, and lock capsules efficiently</h2>
The ProFiller 3800 Capsule Filler from Adelphi is designed to accommodate large-scale pharmaceutical capsule production. Capable of processing up to 9,000 capsules per hour, it efficiently orients, separates, fills, and fully locks 300 capsules at a time. This system maintains high accuracy with a fill weight variance of ± 1-3%, adhering to USP/EP methods. Constructed from 316L pharmaceutical grade stainless steel, it ensures hygienic operation and durability. The ProFiller 3800 includes interchangeable change parts for capsule sizes 00 to 4 and offers optional accessories such as powder vibrators. Its patented design is up to 35% faster compared to similar systems, increasing productivity and reducing operational costs.

Capsule filling system for pharmaceutical production

In pharmaceutical manufacturing, efficiently filling capsules with precise dosages is crucial for quality control and compliance with industry standards. Traditional large-scale filling solutions may not suit smaller production batches or complex formulations, posing challenges in scalability and flexibility.
<h2>Ensure accurate and flexible capsule filling</h2>
The Modu-C CS by Harro Hoefliger is a versatile capsule filling system designed for commercial applications on a smaller scale. It leverages robust processes including segment turret, in-process control (IPC), and 100% weight control to ensure smooth and transparent production. This system excels in dealing with small product quantities and complex rheological properties using advanced feeding and dosing technology. The patented trolley system allows for rapid changeovers between different dosing systems, such as powders, pellets, tablets, mini tablets, and liquids, maximizing flexibility and minimizing downtime. The Modu-C CS can handle various capsule sizes (000 up to 5) and achieve an output of 43,500 capsules per hour. Its intuitive operator controls and easy cleaning procedures make it user-friendly while maintaining high production standards. Integrated with Process Analytical Technology (PAT) and IPC, it ensures precise control over each capsule's weight, making it suitable for various pharmaceutical applications.

Commercial capsule filling for small scale production

In pharmaceutical manufacturing, handling highly active substances demands stringent safety protocols for both operators and products. Issues such as product contamination and operator exposure need to be prevented, especially when dealing with highly potent compounds.
<h2>Ensure safety and precision in capsule filling</h2>
The Modu-C CS Containment from Harro Höfliger is a capsule filling system designed for high containment operations. It allows the processing of products up to OEB 5 classification, ensuring both operator and product safety. Key features include an integrated deduster and cleaning system (WIP) for optimal handling and reduced space requirements. Its 100% gross weighing under containment conditions sets it apart, offering precise weight control. The patented trolley system allows quick dosing system changeovers, enhancing flexibility and modularity. The Modu-C CS also supports various capsule sizes and filling units, making it versatile for different pharmaceutical applications.

High-containment capsule dosing and filling system

In large-scale pharmaceutical production, ensuring efficient and accurate filling of capsules with various substances such as powders, pellets, and tablets is critical. High production demands often require equipment that can quickly switch between different filling processes without significant downtime.
<h2>Facilitates rapid and versatile capsule filling</h2>
The Modu-C HS from Harro Hoefliger is a high-speed capsule filling system designed for maximum productivity. It features a patented trolley system that allows rapid changes between dosing methods, including powder, pellets, tablets, mini-tablets, and liquids. This system minimizes setup and downtime, enhancing operational efficiency. The machine supports all common capsule sizes and can produce up to 200,000 capsules per hour. Additional functionalities include a no-cap-no-fill feature to reduce product loss, a capacitive weight inspection sensor for precise dosing, and comprehensive capsule inspection mechanisms to detect deformed capsules and ensure quality. The compact design and color touchscreen facilitate easy operation and cleaning, making it particularly suitable for pharmaceutical applications.

Capsule filling system for powder, pellets, and tablets

In pharmaceutical research and development, testing new active ingredients and producing small batches often require stringent user protection due to potential exposure to hazardous substances.
<h2>Ensure safe and controlled capsule filling</h2>
The Modu-C LS Containment from Harro Höfliger is a specialized capsule filling system designed for lab-scale and small batch production where high user protection is essential. This system, suitable for OEB Class 4 substances (1-10 μg/m³), incorporates a patented trolley system for rapid and flexible dosing system changes. It features the Modular Advanced Barrier System (MABS), providing robust containment while maintaining accessibility through large operator entries. The system offers a variety of dosing units, including drums, dosators, tamping stations, and options for pellets, tablets, mini-tablets, and liquids. With its no-cap-no-fill function, it minimizes product loss, and the integration of differential pressure measurement ensures precise control and inspection of capsules. The compact design facilitates easy operation and cleaning while supporting PRP functions for person-reduced production. It supports up to 25,000 capsules per hour and accommodates all common capsule sizes, making it ideal for producing test material for clinical studies, double blinding, and small batch productions.

Containment capsule filling system for lab and small batch production

In the pharmaceutical industry, high-precision and flexibility in capsule production are crucial when dealing with varied formulations, from powders to liquids. Consistency and efficiency are key challenges to address, particularly for medium-scale production environments.
<h2>Ensures consistent and accurate capsule filling.</h2>
The Modu-C MS by Harro Hoefliger is designed for reliable and flexible capsule production. It features a patented trolley system allowing fast changes between different dosing systems for powder, pellets, tablets, mini tablets, and liquid. The Modu-C MS is noted for its user-friendliness, with minimal setup and downtime during format changes and cleaning. The system includes enhanced quality control features, such as a calibration bar to detect deformed capsules, and various inspection mechanisms to ensure only correctly formed capsules proceed. It supports production outputs of up to 100,000 capsules per hour and can handle all common capsule sizes. Ideal for medium-range pharmaceutical manufacturing, it ensures easy, efficient, and precise capsule filling.

Versatile capsule filler for pharmaceuticals

In the pharmaceutical industry, precise dosing of powders is critical during the development of new formulations and for producing small batches for clinical trials. This process demands flexibility, accurate dosing, and the ability to handle both effective and toxic materials safely.
<h2>Achieve precise dosing for development and small batches</h2>
The Omnidose by Harro Höfliger is designed to meet all requirements for product development in galenics, enabling semi-automatic production of small batches and clinical trial samples. It offers multiple dosing principles to accurately dose all forms of powder. With barrier technology, it ensures safe processing of highly effective and toxic products. The trolley design enables quick switching between various dosing processes, reducing setup times and enhancing productivity. The system is user-friendly, with easy maintenance, and is capable of being scaled to production standards thanks to standardized processes. Suitable for filling capsules, devices, blisters, discs, powder reservoirs, vials, and cartridges, the Omnidose offers dosing volumes from approximately 20 mm³ to 1000 mm³ and a dosing range of 10 to 5000 mg.

Powder dosing system for development and small batches

In pharmaceutical production, precise and flexible capsule filling is crucial for maintaining product quality and meeting industry regulations. Traditional capsule fillers may struggle with multi-product dosing, variable dosage requirements, or rapid production speeds, leading to inefficiencies and potential quality issues.
<h2>Achieve accurate multi-product dosing</h2>
The ADAPTA by IMA is a state-of-the-art capsule filler designed to meet the demanding needs of pharmaceutical manufacturing. With its ability to dose up to three products into the same capsule (up to five upon request), the ADAPTA offers unparalleled flexibility. It features 100% weight control, ensuring precise dosage for each capsule. The ADAPTA's innovative sensors and machine learning algorithms allow for real-time adjustments, enhancing product quality and reducing waste. Additionally, it supports a wide range of dosage forms including powder, pellets, tablets, minitablets, and liquids. The ADAPTA 50, 100, and 200 models offer maximum outputs of 50,000, 100,000, and 200,000 capsules per hour respectively, making it suitable for varying scales of production.

Capsule filler for multi-product dosing

In pharmaceutical research and development, precise micro-dosing and solid product filling are essential for ensuring accurate dosage and process scalability. Traditional methods often lack the precision and scalability needed for effective capsule filling, especially in early-stage product assessments.
<h2>Dose Dpis or solid products with precision</h2>
The MINIMA by IMA is a table-top capsule filler designed specifically for dosing dry powder inhalers (DPIs) or solid products into hard capsules. This system excels in micro-dosing applications, providing precise dosages with a single dosator. MINIMA supports all capsule sizes and dosages, and is equipped with the same dosing devices found on standard production machines, making it completely scalable. Portable and needing only compressed air, MINIMA features an adjustable powder bowl and an accurate scraping system with a powder recovery ring, ensuring efficient use of materials. Designed with minimal user requirements, the system facilitates easy operation and maintenance.

Table-top capsule filler for micro-dosing

In the pharmaceutical industry, ensuring precise and efficient dosing of capsules is crucial to maintain the consistency and efficacy of medications. Challenges such as dosage uniformity, speed, and operator dependency need to be addressed to optimise production processes.
<h2>Achieve precise dosing and high-speed filling</h2>
The PRACTICA by IMA is a capsule filler designed to meet a variety of straightforward capsule filling requirements in pharmaceutical applications. It excels in dosing powders, granulates, or pellets with high accuracy. The machine offers two models: PRACTICA 100, which can produce up to 100,000 capsules per hour, and PRACTICA 200, capable of producing up to 200,000 capsules per hour. Both models feature a user-friendly interface that enhances operator efficiency and ensures prompt responsiveness. Additionally, the system can be equipped with a statistical weight-checking unit to monitor production and automatically adjust settings to maintain consistency. The PRACTICA system is engineered for easy inspection and cleaning, minimizing downtime and increasing overall productivity.

Capsule filler for pharmaceutical applications

Ensuring accurate weight control in pharmaceutical production is crucial to comply with regulatory standards and guarantee product efficacy. When handling high volumes of capsules, precision in weighing is essential to maintain consistent quality and avoid costly reworks or rejects.
<h2>Achieve precise weight control</h2>
The PRECISA by IMA is designed to provide 100% weight control and selection of pharmaceutical products packed in hard gelatin and HPMC capsules. With a compact design that saves space in production areas, PRECISA combines high production speeds with precise weighing accuracy. A reliable product transfer system minimizes vibrations, ensuring accurate weight measurements. Out-of-weight products are automatically rejected into a specific container. The machine also features a quick size changeover, fail-safe rejection of faulty capsules, and the ability to connect inline with all capsule fillers currently on the market. It can weigh capsules ranging from 1 to 2,000 mg with a standard deviation accuracy of ± 1 mg. The system is efficient and designed to minimize downtime due to its automatic unclogging of feeding channels.

Precision weight-checking for pharmaceutical capsules

In pharmaceutical production, ensuring accurate and efficient counting, filling, and capping is crucial to meet regulatory standards and maintain product quality. Manual operations or outdated systems often lead to discrepancies and increased labor costs.
<h2>Accurate counting and efficient filling</h2>
The UNILINE by IMA is an integrated system designed for the precise counting, filling, and capping of pharmaceutical tablets and capsules. This system consists of multiple key functions, including container loading, desiccant insertion, counting and filling, cotton insertion, capping, and rejection. UNILINE is equipped with advanced Optical and Electronic Field Sensors (E.F.S.) to ensure high counting accuracy, even in challenging conditions. This system offers a flexible solution, eliminating the need for product or bottle change parts, allowing for quick changeovers. The balcony design ensures easy cleanability and visibility, minimizing hidden entrapment points. Compact in size, it requires less space compared to traditional systems, providing high overall equipment effectiveness (OEE).

Integrated counting system for tablets and capsules

In pharmaceutical manufacturing, accurate and efficient capsule filling is crucial for maintaining dosage consistency and production speed. Traditional manual methods are often time-consuming and prone to errors, demanding more advanced solutions to ensure high-quality output.
<h2>Achieve precise dosing and high throughput</h2>
The ZANASI and ZANASI PLUS by IMA are advanced automatic capsule fillers designed to ensure versatility and precision in capsule filling processes. These machines can handle various types of dosing, including powders, pellets, tablets, minitablets, and liquids into hard gelatine capsules. Their ergonomic design allows easy access to the working area, requiring no skilled operators. The ZANASI series offers output capacities ranging from 6,000 to 40,000 capsules per hour, while the ZANASI PLUS series ranges from 16,000 to 70,000 capsules per hour. These machines have low size changeover and cleaning times, making them efficient for continuous production. The technical specifications include models with different capsule capacities and configurations, ensuring a suitable option for different production scales.

Automatic capsule filling machines

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 filling

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