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Capsule Containment Equipment

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

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

Used in the pharmaceutical industry to produce tablets and capsules, among others, pharmaceutical granules are made to enhance the uniformity and flow of powder, increase the density of the blend and reduce dust and, therefore, toxic exposure. The choice of the granulation process, whether it is wet, dry, or direct compression, as well as the selection of appropriate pharmaceutical granulation equipment, depends on the specific drug being formulated.

Pharmaceutical granules

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

API making equipment must observe rigorous quality control standards across the entire manufacturing process. The pharmacodynamic properties of active pharmaceutical ingredients API make them highly sensitive to their environment, making API manufacturing and production a tightly regulated field.

Active pharmaceutical ingredients (API)

The click and puff of inhalers is a universal signal for respiratory conditions. Inhalers quickly grew into preferred drug delivery systems for asthma and COPD. Dry inhaler powder formulation produces a more stable drug than liquid dosage forms. Moreover, inhaler ingredients are more resistant to bacterial growth.

Dry inhaler powder

Around a third of your natural protein composition is collagen. But the human body still finds good use for more of it, whether to reinforce joints or aid digestion. Collagen powder processing breaks the chains of amino acids into smaller units, allowing them to be consumed at higher concentrations without changing your diet.

Collagen powder

During crime scene investigations in any movie, you've probably seen forensic scientists collecting evidence and biological samples in small containers. Here, these are the vials, used to store medicines, especially in liquid form, or laboratory samples. Often made of glass or plastic, vials can be labeled as single-dose vials or sterilized and reused more than once. They are also available with various closure systems depending on the material and storage requirements.

Vials

A pre-filled syringe or PFS is a single-dose disposable syringe that is supplied loaded with the substance to be injected. By using a pre-filled syringe filling machine, you can have excellent dosage accuracy due to the exact filling of medications. During administration, safety from potential contaminants is also ensured as they are directly injected after opening. To further minimize the risk of contamination, pre-filled syringes are often filled and sealed in a sterile environment using stainless steel equipment.

Pre-filled Syringes

After being used to contain the blood of martyrs after death or to store the anointing oil of French monarchs, today ampoules are the first choice in packaging injectables. You create ampoules by melting the glass tube into the desired shape and seal them at the neck by melting the top of the glass tube. The only way for you to extract the contents from an ampoule is by breaking the glass at its breaking point, making it perfect for single dose applications only.

Ampoules

Some of the vaccines in use today were originally developed decades ago. But advances in research, expertise and vaccine development equipment provide immunizations from bacterial and viral diseases (antibodies and cell therapy) to more people every year. The Covid 19 pandemic highlights the urgent need to scale up the production of vaccines and ensure an automated as well as reproducible manufacturing environment.

Vaccines

The word parenteral comes from Greek and means outside the intestine (para=outside and enteron=intestine). In fact, when it comes to parenterals, we are referring to those dosage forms that are administered directly into the bloodstream using a hypodermic needle, avoiding going through the gastrointestinal tract. Using parenteral filling equipment, parenteral solutions are placed in containers such as vials, syringes, or ampoules.

Parenterals

Low cost manually operated single port testing device

Constructed of acetyl or 316L stainless steel

It can be designed to suit all types of Telstar ACE glove ports as well as other port brands

Contained transfer systems are designed to safely transfer the product or waste items in or out of contained or sterile areas. Valves are used to regulate the flow in contained transfer systems. The choice of a suitable containment system depends on the form of source and target containers, the physical state of the product and the volume of the product to be transferred. These systems find applications in transferring pharmaceutical powders from drums to the process equipment, filling bulk chemicals in transportation bags or safely discharging them into mixing tanks.

Contained transfer systems

Pharmaceutical

Containment Technology

The essential objectives of containment systems are personnel protection and preventing the release of toxic or infectious material into the environment. Containment is also used to prevent a product or sample from contamination by the external environment. In the chemical and pharmaceutical industries, containment solutions are used to protect the personnel from the leaking of airborne particles of hazardous substances, as powders or liquids are handled or transferred during processing.

Containment

Connect directly with world leading manufacturers of containment technology equipment and find technology to build or improve your production line.

Containment - Making.com

Containment Technology - Making.com

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

Cannabinoids are natural compounds obtained from the Cannabis sativa plant. Delta-9-tetrahydrocannabinol or THC is a psychotropic substance. Cannabidiol, or CBD, is non-psychotropic and often used for nutraceutical purposes. Cannabinoid equipment extracts THC and CBD from the plant and prepares the substance for formulations that treat pain, nausea, anxiety, and inflammations. Cannabinoids are processed in various forms, including creams, capsules, and oils.

Cannabinoids

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

Pharmaceutical powders provide longer shelf life and better stability than liquid dosage forms. But the processing of pharmaceutical powders is crucial for growing segments besides pharmacy. Functional foods and cosmetics formulated with active ingredients and excipients depend on powdered forms to fulfill their promises.

Pharmaceutical powder

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

The building blocks of matter have driven the imagination of philosophers, scientists, and artists for millennia. But, for manufacturers, these elements have a more concrete existence as powders. Powder processing technology conditions these primary materials to create a vast range of products, from chemicals and foods to pharmaceuticals and ceramics.

Powder

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

Packaging

Process

R&amp;D

Safety &amp; Environment

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

Drawing samples and testing them for conformity with preset quality standards allows manufacturing units to produce a consistent quality of the product. In a batch process, sample testing systems ensures that each batch meets the specified standards. In a continuous process, product and materials testing helps in the early identification of quality issues, saving significant time and resources, and preventing a sub-standard product from reaching the market. The selection of industrial testing equipment depends on the identification of key quality parameters. These parameters may include volume, weight, viscosity, hardness, particle size distribution, sterility, gauge and containment, among other parameters. Testing machinery need regular calibration to ensure that the parameters being tested are accurate. Some of the more common testing solutions include thermal imagers, scratch testers, optical inspectors and texture analyzers.

Testing

liquid

solid

Glove Tester from Telstar Life-Sciences is a low cost manually operated single port testing device designed to allow both in situ and offline testing.

Testing device of the containment capability of gloves, which is as important as the other parts of the integrated system; and a simple, accessible means

Glove tester - Making.com

https://making-tst.imgix.net/2014/12/Glove-tester.jpg

The marketplace for finding innovative production technology

Making.com

Integrated system

  Easy measurement of half-suit containment efficiency

Allows both in situ and offline testing

316L stainless steel base

A flexible containment solution prevents product loss and ensures that personnel is not exposed to harmful substances by locking in the product as it is transferred from one container to another. The choice of a containment system depends on the physical state of the product, the type of container from which the product is being transferred, and the type of container to which it is being moved. Flexible containment solutions are widely used in the pharmaceutical, food, and chemical industries to comply with health and safety regulations.

Flexible containment solutions

The Half-suit tester from Telstar life-Sciences is the most likely component of the isolator which mission is to suffer wear, tear and thus develop leaks.

Designed to allow operators to perform sterility testing in an aseptic environment providing assurance of material integrity. For ultimate containment of

Half-suit tester - Making.com

https://making-tst.imgix.net/2014/12/Half_Suit_Tester.jpg

Suppositories consist of active pharmaceutical ingredients encased in a non-active base material. The sustained release of medication makes suppositories a preferred option for the long-term treatment of chronic conditions like diabetes, anemia, and AIDS.

Suppositories

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

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

A dishwasher tablet is an essential detergent. It consists of a pressed mixture of sodium and potassium salts, surfactant, fragrance, and other filler agents, mixed with the help of tablet making machines. The products’ use in America and Europe is high, unlike in the Asian continent, where the price limits its usage. Its global market size will reach $990 million in 2026 from $475.6million in 2019, according to Grand View Research forecasts.

Dishwasher tablets

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

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

The wave of liquid soaps and detergents in the 1950s revolutionized home and personal care. Cheap and convenient, these off-the-shelf products fit perfectly into the lifestyle of the time. A few decades later, though, plastic waste put the sustainability of hygiene products into question. Refill tablet production technology answers that by eliminating single-use plastic. Instead of picking up a new bottle every time, end-users complete the formulation process in a multi-use container and with a simple instruction: just add water.

Refill tablets

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

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

There are slight differences between human and animal pharmaceuticals, but that dissimilarity is enough to create new production challenges. Veterinary tablets formulation reflects the diversity of enzymes that different species use to break down substances. Although the methods involved are comparable to human drug manufacturing, equipment and processes need to adapt to a wider dosage variability in veterinary tablets.

Veterinary tablets

Patented ZRM technology for optimized yield and minimal dusting

Left -over of 20-50 grams depending on the model, output, and formulation characteristics

No Capsule-No Slug feature reduces further reduces formulation loss and dusting

Micro-dosing capability with +/- 2 mg accuracy

Optional Rapid Transfer Port

The two halves of a capsule shell are separately filled with your selected material before they are then pressed against one another and closed. Automatic capsule fillers orientate the shells in the precise position, fill them with your specified formula a join the ends. Capsules are then de-dusted and polished by micro brushes before they are ready for packaging.

Capsule fillers

Batch

Continuous

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

Formulation technologies are an integral process in many industries such as pharma and food. Chemical mixtures require strict handling to combine the separate ingredients into the homogenized recipe that makes your final product. Formulation technology stores, mixes and subjects the elements to a range processing parameters according to your specifications to develop the base material. The resulting formulas are then weighed, formed, packaged, or sent for further formulation.

Formulation

<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

The Securefill 12T from ACG-Pam is a fully automatic contained capsule filler for highly active substances.

For pharmaceutical formulations that are highly active specialized capsule filling equipment is often required for operator safety and protection of

Contained capsule filler - Making.com

https://making-tst.imgix.net/2015/07/7Securefill12T-scaled.jpg

sensum_spine_hypo_brochure_en-pdf

Sensum_SPINE_HYPO_Brochure_EN.pdf

<em>“How clean does my equipment needs to be?” </em>That's what manufacturers often wonder about in order to meet the high sterilization standards the pharmaceutical industry demands. Lending manufacturers helping hand have been single-use bags, also known as disposable, first introduced in the late 1990s. They immediately gained popularity because they reduce the risk of cross-contamination, minimalize cleaning and sterilization demands, and require a low capital cost.

Single-use bags

Surgical instruments still involve a significant degree of manual craftsmanship to manufacture. But advances in surgical instruments technology today intertwine with expert handiwork to produce precise tools that make the difference between life and death.

Surgical instruments

Highly autonomous inspection

Safe inspection even for highly toxic products

High throughput inspection and sorting

Simple cleaning using dry/wet approach

To claim that a tablet meets quality requirements, you must perform several inspections to ensure its efficacy and patient safety. In addition to the tests described in official compendia such as weight variation test or dissolution test, visual inspection or metal detection are equally important. Metal detection identifies ferrous, non-ferrous, or stainless steel contaminants in tablets while visual inspection can detect defects such as color deviations, bubbles, or cracks.

Tablet inspection system

Industrial inspection equipment is used for checking compliance with health, safety, and quality control standards. For that reason, inspection systems are most commonly utilized in the food and pharmaceutical industry but, they are also used in other industries too. Inspection solutions are often integrated into a production process or production line. Visual inspection systems perform checks to detect variation in size, shape, and color and ensure the presence of labels and closures. Check-weigh systems help ensure that product packages are not under or over-filled. Metal detection systems can help guard against the presence of foreign objects in product containers and X-ray inspection equipment is used to detect physical defects and to ensure high quality package seal integrity.

Inspection

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

In the medicine industry, it is important to ensure there are no defects in tablets or capsules. However, it’s a challenging task when combining

Contained Visual Inspection System - Making.com

https://making-tst.imgix.net/2021/01/SPINE-HYPO-small.jpg

Insulin is a hormone that controls blood glucose levels produced by the beta cells in the pancreas. As a medication, insulin was discovered by Frederick Banting and Charles Best in 1921, for which Banting was awarded a Nobel Prize in 1923. The insulin production process involves manipulating the biological precursor to insulin and cultivating it inside bacteria using specialized technology.

Insulin

Complies fully with ISO 14644-7:2004 producing an EU GMP Grade A environment throughout the chamber

A minimum of log 6 reduction in spore forming micro-organisms is consistently achieved & validated using a BI challenge

  Sound ergonomic design of the unit is combined with thoughtful design-for-manufacture utilizing the latest techniques, assuring ease of assembly and efficient inspection and testing

Barrier isolator systems create a physical and an aerodynamic barrier between the operator and the work process. The product or process inside the isolator can only be manipulated through the use of gloves or a robotic arm. Choosing an isolation system involves considering the safety regulations (for example; operator protection or cGMP standards), positive or negative pressure specifications, and monitoring and control requirements. Barrier and isolator systems are used in the pharmaceutical industry for sterile processes such as injectable drug filling and cytotoxic drug compounding. Barrier systems and isolators are integrated into full production lines and the most important thing is to control and monitor airflow.

Containment isolators

Logistics

The Sterility test isolators from Telstar Life-Science range of rigid wall Sterility are designed to avoid this risk.

Designed to avoid this risk and protect the product from both the process and externally generated factors that would compromise its quality. Perform

Sterility test isolators - Making.com

https://making-tst.imgix.net/2014/12/Sterility_Test_Isolator.jpg

Simplicity in design with 304/316L stainless steel Frame

Fully opening vision panels in 10mm toughened safety glass or laminated glass

Uni-directional downward laminar flow over the whole area of the RABS at 0.45m/sec +/- 20% provided by either micro-perforated

 grill or polyester air distribution screen

Pressure monitoring of filter differentials using 'magnehelic' pressure gauge

Automated air velocity control to compensate for filter burden

Telstar Life-Sciences’ RABS provide protection by delivering an aerodynamic barrier over a critical process zone and bio-decontamination is usually manual.

Create a physical barrier between the operator and the product. More flexible than an isolator, a RABS is open, in most cases, so the air flows freely out

Restricted-access barrier systems - Making.com

https://making-tst.imgix.net/2014/12/RAB.jpg

Increased efficiency

  Automation

Flexibility

Protected critical zones

Environment free from pathogenic microorganisms

The aseptic barrier systems from Telstar Life-Sciences work providing product protection in all process areas against external environment, operator and bacterial growth contamination.

Designed for sterile product and Potent API’s either with low or high OEL requirements. Advanced aseptic processing from full filling lines to stand alone

Aseptic barrier systems - Making.com

https://making-tst.imgix.net/2014/12/Aseptic.jpg

Microprocessor air flow control equipped with one sensor

Front window placed under a small angle for ergonomics, easily removed for maintenance

Stainless steel dripping tray underneath the air grids to remove spoil liquids

Glove systems (2 or 4), portsØ250 mm, with cuff ring system and latex gloves

Lighting unit constructed outside the working area, lighting level > 1000 lux

A biosafety cabinet is an enclosed, ventilated workspace for safely working with materials potentially contaminated with pathogens in the laboratory. A laminar flow bench is an enclosed space designed to prevent contamination of sensitive samples; it draws in air through a HEPA filter and directs it smoothly towards the user to protect the sample from contamination. The choice of a suitable biosafety cabinet or bench depends on the type of sample and the defined biosafety level ranging from 1 (unlikely to cause disease) to 4 (causes very serious human or animal disease).

Biosafety cabinets

The Cytolator from Telstar Life-Science is a negative-pressure isolator, which works providing laminar airflow within the working chamber.

Used for products biologically hazardous, that also require minimized cross contamination. Start working with hazardous substances thanks to this

Negative pressure isolator - Making.com

https://making-tst.imgix.net/2014/12/cytolator-LR.jpg

<h3>Mold the shells into shape with capsule manufacturing equipment</h3>
Capsule shells are composed of the body and the cap that closes the dosage. Capsule manufacturing equipment dips a series of steel pins into a drum filled with the base material. The wet molding pins move to the drying chamber to harden as they spin on their axis to ensure even distribution.

Once the shells are formed, they are stripped off the pins. But they are not yet finished for filling. The empty capsules must first be cut to the correct length and joined in a pre-lock position, ready for encapsulation.

Encapsulation technology lines up the capsule bodies on a bed of holders. A stainless steel dosage system pours the formula in the powder tray into the shells. The caps, aligned precisely in their holding section, are ready to be lowered onto the filled capsule bodies. The fins in the body enter the slits of the cap, locking them into position.

The encapsulated ingredients directly impact shell stability. Hygroscopic materials, for example, risk cracking the gelatin capsules. Capsule filling machines must account for the properties of the dosage formula and the materials, thickness, and shelf life of the shells.

Capsule production is either an automatic, semi-automatic or manual process. Manual capsule fillers are still used in smaller production facilities. However, for making large scale pharmaceutical capsules, automation is employed to maximize output and efficiency.

Capsule Containment Equipment

Which capsule containment technology do you need?

Glove tester

Half-suit tester

Contained capsule filler

Contained Visual Inspection System

Sterility test isolators

Restricted-access barrier systems

Aseptic barrier systems

Negative pressure isolator

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