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Maker - Product Challenge

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Capsule Filling 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

brochure_multigel_suppositoriesmachine-pdf

Brochure_Multigel_SuppositoriesMachine.pdf

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

Full temperature control of the molten compounds ensuring consistency and quality

Reel-based system for rapid loading and unloading

Wide dosage range available to meet your exact requirements

Full GMP design with FDA-approved materials

Easily combines with S-MND 6000 to complete a suppository production line

Pharmaceutical

Filling lines

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

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

Filling - Making.com

Filling Lines Equipment - Making.com

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

Liquid

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

Process

Continuous

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

liquid

Small-to-medium scale production of suppositories using pre-formed shells can be slow where manual filling is used. An automated filling solution that can

Suppository filling machine - Making.com

https://making-tst.imgix.net/2019/06/suppositories-machine.jpg

The marketplace for finding innovative production technology

Making.com

brochure_multigel_automatic_counting_line-pdf

Brochure_Multigel_Automatic_counting_line.pdf

Economical way to upscale production of solid doses

Can count and fill a wide range of sizes and shapes of doses

High throughput for increased efficiency, up to 200,000 doses per hour

GMP design, with 316 stainless and FDA-approved materials

Touchscreen controls and monitoring for minimal operator input

Eating is more than just nutrition, but we have found ways to increase the nourishing power of our foods. Nutraceuticals manufacturing, from vitamin C powder and probiotics to omega 3 oil, is a concentration of natural ingredients and health supplements that complement our diets. While dietary supplements are not quite haute cuisine, the process of extraction and purification is no less a blend of science and art.

Nutraceuticals

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

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

solid

For medium-scale production of solid doses such as tablets, capsules, and softgels that are provided in standard counts, an automated counting and filling

Automatic filling line for solid doses - Making.com

https://making-tst.imgix.net/2019/06/capsule-line.jpg

acg_world_1193_brochure-pdf

ACG_World_1193_brochure.pdf

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

Pelleted feed

Handles viscosities up to 40,000 cP

Reduces waste with 'no-capsule-no-fill' sensors

Supports oxygen-sensitive formulations

Versatile filling for various capsule ingredients

High output for medium to large batches

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

Industrial

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

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

In the pharmaceutical industry, producing liquid-filled hard capsules with precision and minimal waste is crucial. Challenges include varying liquid

Liquid filling system for hard capsules - Making.com

https://making-tst.imgix.net/2024/09/ACG_World_1193_image.png

acg_world_1192_brochure-pdf

ACG_World_1192_brochure.pdf

Liquid soup

In 1682, Denis Papin found a method to remove collagen from animal bones, discovering gelatin. But it was the inventor Peter Cooper who developed gelatin powder processing. In 1845 he secured his invention with US patent 4084 for a dessert of gelatin powder called “portable gelatin”.

Gelatin powder

Optimizes space with integrated filling and sealing operations

Reliable filling for a wide range of viscosities

Ensures capsule integrity and extends shelf life

Efficient for R&D and pilot-scale production

Supports multiple capsule sizes and types

Form, fill, and seal machines complete the packaging, filling, and sealing in one continuous process and eliminate the need for three separate machines. Most form, fill and seal systems use flexible films to form the primary package. Vertical machines are simpler and faster whereas horizontal systems are better suited to the packaging of solid products that do not flow well. Form, fill, and seal machines are widely used in the food industry for packaging snack foods, powdered products, liquids, and pastes and in the pharmaceutical industry for the production of IV bags, powder sachets, and stick packs.

Form fill sealing equipment

Cooking liquid and semi-solid foods like jams and sauces is a time-intensive process. Sealed thermal cookers speed up the step by cooking in a vacuum or under pressure. Besides greater time efficiency, vacuum cooker technology retains nutritional properties, texture, and flavors. The choice of a suitable thermal vacuum cooker depends on the batch size, cooking temperatures, and vacuum/pressure requirements. These parameters vary on the recipe and product type. One of the main considerations when selecting vacuum cooking technology is the cleaning process following use. An easy and quick cleaning system reduces downtime and maximizes on-site operations.

Vacuum cookers

Healthcare products are goods or services used to improve, maintain or prevent the deterioration of health or ease the consequences of illness. Healthcare products include a wide range of goods, from hospital clothing, over plasters, wound care products and diagnostic devices. These products must be clean and contamination-free, which is achieved with strictly regulated healthcare equipment.

Healthcare products

<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

Pilot

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

Sealing

In R&D or pilot-scale production, ensuring the integrity of liquid-filled capsules is critical. Challenges include precise dosing, effective sealing, and

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

https://making-tst.imgix.net/2024/09/ACG_World_1192_image.png

adelphi_1308_brochure-pdf

Adelphi_1308_brochure.pdf

High output of up to 9,000 capsules per hour

Accurate filling within ± 1-3% of the average weight

Pharmaceutical grade 316L stainless steel construction

Hygienic and durable design

Interchangeable parts for flexibility in capsule sizes

Packaging

Separating

In the pharmaceutical industry, ensuring precise dosing and minimizing waste are critical during capsule production. Addressing such requirements calls

Capsule filling system for pharmaceutical production - Making.com

https://making-tst.imgix.net/2024/09/Adelphi_1308_image.png

adelphi_1307_brochure-pdf

Adelphi_1307_brochure.pdf

High production rate of up to 3,400 capsules per hour

Precise fill weight accuracy reduces material waste

Constructed from durable, hygienic 316L stainless steel

Easy operation and maintenance

Versatility in handling multiple capsule sizes and powder types

Entry level

Powder

When producing pharmaceutical or nutraceutical capsules, achieving consistent fill weights and maintaining a hygienic production environment are crucial.

Capsule filling solution for small to medium batch sizes - Making.com

https://making-tst.imgix.net/2024/09/Adelphi_1307_image.png

cremer_3228_brochure-pdf

Cremer_3228_brochure.pdf

Maintains 100% counting accuracy

High throughput of up to 200 bottles per minute

Easy to clean and maintain

Capable of handling various bottle shapes and solid dose types

Ensures product quality with Single Tablet Reject function

Bottle filling equipment entails transferring your products to a bottle which involves inspecting the material, and then conveyors feed it into the machine which then pours it into the vessels using volumetric technology and nozzles before capping them. Bottle filing varies not only in product type but in the size, shape, and material of the container too. Depending on your operation, filling systems may adopt in-line or rotary methods before transferring the bottles to the next stage of processing.

Bottle filling equipment

Counting

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

In pharmaceutical manufacturing, filling bottles with precise quantities of solid dose products like pills, tablets, and capsules is vital for maintaining

In-motion bottle filling system for pharmaceuticals - Making.com

https://making-tst.imgix.net/2024/09/Cremer_3228_image.png

images-html

images.html

Accurately fill capsules with multiple dosage forms

Integrated 100% gross weight control ensures precision

Quick set-up and changeovers with patented trolley system

Handles small product quantities and complex formulations

User-friendly with intuitive controls and easy cleaning

Batch

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

Weighing

In pharmaceutical manufacturing, efficiently filling capsules with precise dosages is crucial for quality control and compliance with industry standards.

Commercial capsule filling for small scale production - Making.com

https://making-tst.imgix.net/2024/09/Harro_Hoefliger_4753_Image.png

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)

High user and environmental protection with MABS containment

Flexible and rapid dosing system changes with patented trolley system

Minimized product loss with no-cap-no-fill function

Ergonomic design for ease of use and maintenance

Supports a variety of dosing units and capsule sizes

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

In pharmaceutical research and development, testing new active ingredients and producing small batches often require stringent user protection due to

Containment capsule filling system for lab and small batch production - Making.com

https://making-tst.imgix.net/2024/09/Harro_Hoefliger_4756_Image.png

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

Rapid changeover with patented trolley system

High production capacity up to 200,000 capsules per hour

Precise dosing with capacitive weight inspection

User-friendly operation and easy cleaning

Fill level inspection ensures that each container is filled with exactly the desired volume of the product during a liquid filling operation. While transparent containers can utilize optical sensors for level detection, difficult to see through containers, such as cans or cartons lined with aluminum, must be scanned using X-rays. When choosing fill level inspection equipment, the size, shape, and opacity of the container must be considered. The production speed, the desired accuracy, and the amount of foaming on the liquid surface are also important parameters to consider. Fill level inspection systems are used to comply with quality control standards.

Fill level inspection systems

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

A tablet press consists of two essential tools, namely dies and punches. It compresses powder or granules into a desired solid substance of uniform size and weight. After filling the dies with powder or granules, upper and lower punches are pressed together within the die hole to form tablets. Then the upper punches come back to their original position while the lower punches help the ejection of the tablet from the dies.

Tablet presses

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

Sorting is the process of arranging items systematically, using a specified criterion, to categorize and group similar items and identify non-conforming items for removal. The choice of a sorting machine depends on the type of item to sort, the sorting criteria, the number of categories that the items need to be sorted into, sorting speed, and accuracy. Sorting machines can be used in the food processing industry for sorting and categorizing fruits, vegetables, empty bottles, crates, and other items; other examples include sorting of tablets and capsules by weight for quality control in the pharmaceutical industry. As well as sorting waste in the recycling industry. Manual sorting is a laborious task however, with the use of specialized equipment, manufacturers are able to automate their sorting at high speeds.

Capsule Filling Equipment

Which capsule filling technology do you need?

Suppository filling machine

Automatic filling line for solid doses

Liquid filling system for hard capsules

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

Capsule filling system for pharmaceutical production

Capsule filling solution for small to medium batch sizes

In-motion bottle filling system for pharmaceuticals

Commercial capsule filling for small scale production

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