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capsule-filler

capsule filler

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

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

Although not all women use makeup every day, almost all of them own at least one makeup product, be it lipstick or face powder. Most makeup products share the same basic ingredients of waxes, oils, and fillers with pigments like iron oxide used for colors and shades. Makeup manufacturing equipment includes pulverizers, mixers, and mechanical press machines to produce cosmetic products in different forms such as powder, liquid, or mousse.

Makeup

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

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

<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

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.

Continuous

Industrial

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

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

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

liquid

Powder

solid

In pharmaceutical manufacturing, ensuring that only high-quality capsules are processed is essential for maintaining product integrity and operational efficiency. Crushed or misshaped capsules can lead to malfunctions and production delays, decreasing overall productivity.
<h2>Automatically select and feed perfect capsules</h2>
The SC SYSTEM by IMA is a capsule selection and feeding unit designed to enhance the productivity of capsule fillers. It effectively separates crushed or ovalised capsules from perfect ones, ensuring only the best capsules are fed into the filling machine hopper. The unit features a continuous rotating wheel equipped with calibrated holes, allowing only correctly formed capsules to pass through. Post-selection, capsules are directed into the machine hopper by an uplifting belt or air blow. The system facilitates straightforward size changeovers and halts or restarts automatically when the capsule load level reaches a set minimum in the filling hopper. It supports production rates of up to 230,000 capsules per hour, depending on the capsule size, and includes various wheel options for different capsule dimensions.

Capsule selection and feeding unit

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

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 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

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

Weighing

Batch

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

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

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

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

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

Entry level

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, achieving both high yield and reliable tablet quality is critical. Traditional methods often fall short when dealing with complex shapes and rigorous production standards, leading to product loss and cross-contamination risks.
<h2>Enhanced tablet production with innovative compression system</h2>
The COMPRIMA by IMA is an advanced tablet press designed to overcome these challenges with its centrifugal force-driven powder feeding system. This system ensures accurate die filling without powder mix segregation, enabling high production speeds regardless of tablet shape. The processing area is isolated with seals and bellows to prevent contamination, and a Clean In Place (CIP) system allows for a fully automatic, validatable cleaning cycle. Suitable for high containment applications (OEL 5), it features glove ports and negative pressure within the processing area for operational safety. The COMPRIMA offers various models with capacities ranging up to 300,000 tablets per hour and is capable of handling round tablets of 5-17 mm and oblong tablets of 5-21.5 mm, with a compression force up to 80 kN.

Tablet press for high-quality pharmaceutical tablets

Pressing

In the coffee production industry, precise and efficient filling and sealing of capsules is crucial to maintaining product quality and meeting high demand rates. Unreliable systems can lead to significant downtime and inconsistency, which disrupts production flow and affects overall profitability.
<h2>Fill and seal coffee capsules efficiently</h2>
The SR SMART Series from IMA is designed to address the intricacies of filling and sealing coffee capsules. This series features an ergonomic cantilever design that ensures easy access for maintenance and cleaning. Its dual-lane configuration allows it to fill and seal capsules with speeds ranging from 60 to 120 capsules per minute. The series supports various capsule materials, including plastic, aluminum, and compostable options. With a fast changeover time and integrated double feeding system, it can handle bulk and stacked capsules seamlessly. Notable features include nitrogen flushing for preserving aroma, precise dosing systems, and the capacity to close capsules with multiple types of lids. The SR SMART Series is tailored towards the coffee industry, enhancing efficiency and reliability in production lines.

Capsule filling and sealing system for coffee production

Sealing

For medium production volumes in coffee processing, achieving high dosing accuracy in capsule filling and sealing can be challenging. The need for a reliable, cost-effective solution that maintains high technological standards in a compact footprint is vital.
<h2>Ensures accurate dosing and efficient sealing</h2>
The SR Series from IMA is a range of versatile, flexible machines designed for the filling and sealing of capsules on 4 and 6 lanes. These systems are equipped with mechanical stations moved by a camshaft system and feature a 15” touch-screen operator panel for easy monitoring. Coffee is dosed through an auger system driven by a Brushless motor, ensuring precise measurements. Additionally, the prearrangement for a nitrogen tunnel maintains product freshness. The SR Series handles various materials such as aluminium film, micro perforated, filter paper, triplex coupled, and PP lids. These machines are suitable for coffee, tea leaves, and any soluble product, making them versatile for diverse applications. They also support the use of compostable and recyclable materials, enhancing sustainability.

Capsule filling and sealing system for coffee products

Manual

For researchers and lab technicians working on small-scale production of coffee capsules, precise control and flexibility during capsule filling and sealing are essential. Ensuring minimal downtime and easy handling of various capsule materials is vital for efficient lab operations.
<h2>Fill and seal coffee capsules efficiently</h2>
The SB1 Lab by IMA is a compact rotary system designed specifically for lab-scale capsule filling and sealing. It features an ergonomic design that ensures easy maintenance, service, and cleaning. The pull-out dosing systems reduce line downtimes significantly. The SB1 can handle Nespresso-compatible capsules in plastic, aluminum, and compostable materials, allowing for fast size changeovers. Capsules can either be manually fed or automatically inserted using a de-stacking unit. It supports various sealing materials including aluminum film, micro-perforated, filter paper, triplex coupled, PP, and compostable lids. The system's production speed reaches up to 25 capsules per minute, with minimal maintenance requirements and precise dosing capabilities. IMA ensures each unit has a reliable production in a modified atmosphere.

Capsule filling and sealing for lab purposes

In many coffee production facilities, precision in dosing and sealing is essential to ensure product quality and consistency. Challenges often include maintaining accuracy, reducing waste, and ensuring compatibility with various capsule types and materials.
<h2>Automate capsule filling and sealing processes</h2>
The MCA Series by IMA is a versatile capsule filling and sealing system designed for efficient and accurate coffee production. These systems are available in configurations with up to 4 lanes, capable of handling up to 240 capsules per minute, depending on the model. The equipment includes a handling chain, input pick & place with heads, and a unique station for cutting and welding filters for both the bottom and top lids. It uses volumetric dosing screws with a weight accuracy of ± 0.2 g, ensuring precise dosing. Additionally, the MCA Series can handle compostable and recyclable materials, making it suitable for sustainable production. The modular design includes options for accessories like nitrogen injection devices, check-weighers, and vision systems, among others, allowing for customization based on production needs.

Capsule filling and sealing system for coffee

Cutting

Welding

When handling capsule packaging at high production speeds, maintaining gentle handling while optimizing space and minimizing waste becomes critical. Companies face challenges of managing a variety of capsule types and carton configurations efficiently.
<h2>Efficiently packs capsules into various carton styles</h2>
The C-900 by IMA is a high-speed cartoning solution designed for handling any type of capsule available on the market. It efficiently packs capsules into a variety of sizes and carton configurations, with a capacity of up to 900 capsules per minute and 90 cartons per minute. Its versatility is enhanced by a capsule transfer feeding system with a buffer and recirculation unit, ensuring gentle handling to prevent damage. The machine can perform quick size changeovers, handling single or multi-layer configurations, and features options for different carton styles, including top flap and flip top closures. The motorization system avoids power waste by sharing kinetic energy generated during braking among other modules. It supports cartons made of recyclable or compostable materials, contributing to sustainability. The compact design facilitates integration with IMA's high-speed capsule filling machines.

High-speed capsule cartoning solution

Cartoning involves erecting a folded carton, filling it with the product, closing the flaps, or applying a lid and sealing with glue or adhesive tape. Choosing a cartoning solution involves, considering the type of primary packaging, the production volume, the size and count of the product in a carton, and the desired level of automation.

Cartoning

Handling

In pharmaceutical production, accurately weighing capsules at high speed is essential for maintaining product consistency and quality. Ensuring that each capsule meets stringent weight specifications prevents issues related to under or overfilling, which is critical for both efficacy and regulatory compliance.
<h2>Achieve precise and rapid capsule weighing</h2>
The Accura-C is a capsule weighing system from Harro Hoefliger designed for high-performance quality inspection. This system weighs pharmaceutical capsules gently yet precisely, ensuring bad capsules are reliably sorted out. The integrated feedback loop allows automatic regulation of capsule filling weight. With an in-line connection to capsule filling machines, including those from other manufacturers, it increases production efficiency. The system features vibration compensation for highly precise weighing results, and minimal setup and cleaning times, making it highly reliable for continuous operation. It supports all common capsule sizes, and works with a measuring range of 0 – 2,000 mg with an accuracy of ± 2 mg.

High-speed capsule weighing system for quality assurance

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.

Sorting

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

Blending

Pilot

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

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 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

Counting

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 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, keeping the capsule filling machines continuously supplied is critical. Manual handling risks contamination and damage, disrupting the workflow and resulting in downtime.
<h2>Gentle and efficient capsule transfer</h2>
The CapsuJet capsule transfer system by Hanningfield Process Systems provides a solution to automate the loading and unloading of capsule filling machines, ensuring minimal capsule damage. The CapsuJet C20 model is designed for empty capsule loading, capable of handling up to 300,000 capsules per hour, while the CapsuJet FCC model transfers filled capsules at a rate of 200,000 per hour. Constructed with 316L stainless steel contact parts and FDA-compliant seals, these systems are suited for all sizes of hard-shell capsules. Optional level control in the filling machine hopper automates the loading process, making it efficient and reliable. The customizable hopper accommodates different batch sizes, and the low noise levels enhance the working environment.

Capsule conveyors for gentle capsule transfer

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

A loading system feeds your continuous or batch processing machine with the specified material or item in line with the flow of production. Loaders transfer the articles from one stage of preparation to the next with uniformity and accuracy.

Loading

In the production of next-generation vapour products, maintaining consistent and high-throughput assembly processes is critical. This is especially true for industries dealing with high-demand consumer markets where precision and efficiency can significantly impact the bottom line.
<h2>Assemble cartridges at 300 cpm</h2>
The E-CA from G.D (Coesia Group) is designed for efficient cartridge assembly specifically targeted at next-generation vapour products. It can achieve throughput rates of up to 300 cartridges per minute, ensuring high production efficiency. The E-CA's versatile design also makes it suitable for hemp-based products, offering flexibility for various market needs. The system's automated processes ensure precision in assembly, minimizing errors and reducing waste. G.D's proven technology supports reliability and consistent quality, making it an ideal choice for industries focusing on vapour and related products.

Cartridge assembler for next generation vapour products

Assembly platforms combine different parts into one final product. Components are inspected for quality and joined or affixed together into the goods. Assembly lines automate the process to ensure consistent quality and integrate into other technologies, such as packaging equipment. But a primary consideration for assembly solutions is their capacity to scale manufacturing processes. Assembly platforms must be adaptable to your long-term volume requirements.

Assembling

In pharmaceutical manufacturing, ensuring each bottle contains the exact count of tablets or capsules is crucial. Mistakes can lead to costly recalls and compliance issues with stringent industry regulations. Precisely counting and filling various solid dose products into bottles is a challenging but essential task.
<h2>Ensures accurate tablet and capsule counting</h2>
The CF 1220 is a 12-channel linear tablet and capsule counter with integrated indexing bottle conveyor, brought to you by Cremer. The counter uses three vibratory plates for optimum product separation and an infrared detection system to ensure 100% accurate counts. It supports 12 or 24 product channels, and can handle different types of tablets and capsules, including hard and softgel variants, filling them into glass or plastic bottles with high precision. The system's infrared detectors can identify unusual shapes and broken tablets, rejecting incorrect bottles as needed. This equipment meets all US and European pharma-grade standards, including GMP and 21 CFR part 11 compliance, making it a reliable choice for pharmaceutical and nutraceutical applications.

Linear tablet and capsule counter

In the production of pharmaceuticals, cosmetics, and health supplements, precise encapsulation of soft gels ensures product quality and cost efficiency. Traditional methods often struggle with maintaining high gelatin utilization and accurate dosing.
<h2>Accurate dosing and efficient gelatin utilization</h2>
The Soft Gel Encapsulation Machine offered by Austar, in partnership with Italian Pharmagel Company, provides high machining precision and stable operation. The die roll's compact holes allow for high gelatin utilization, minimizing waste and reducing costs. Equipped with a wear-resistant metering pump, the system ensures high filling accuracy, enhancing product quality. The servo-driven design with synchronous position angle encoder adjustment guarantees good sealing of soft gels and prevents leakage. The machine uses FDA-compliant materials and features an effective separation of operational and mechanical areas, facilitating easier maintenance and inspection.

Soft gel encapsulation system

For high-speed commercial manufacturing of biopharmaceutical products, maintaining sterility and precise filling is crucial. Common challenges include ensuring in-process control, compliance with GMP standards, and flexibility to handle different vial sizes.
<h2>Enables high-speed aseptic vial filling</h2>
The Crystal™ PX Filling Line by Aseptic Technologies is designed to meet the demands of biopharmaceutical manufacturing. Utilizing AT-Closed Vial® technology, this platform ensures 100% in-process control and full GMP compliance. The system offers a flexible capacity, processing up to 180 vials per minute, depending on the configuration. Custom-built according to user specifications, it can be equipped with a safety barrier for high-class cleanroom environments or installed within a Restricted-Access Barrier System (RABS) with H2O2 decontamination. Featuring automated vial loading, it supports filling volumes ranging from 0.1 ml to 50 ml with high accuracy and tool-less format change. The Crystal™ PX Filling Line is ideal for cell and gene therapy products, exosomes, viral vectors, and plasmid DNA, making it a versatile solution for novel biopharmaceuticals.

Aseptic filling line for biopharmaceutical products

Industrial disinfection equipment use antimicrobial agents to destroy microorganisms found on machines, floors, walls, and other surfaces. In industry, disinfection of machinery and the production area is important to prevent product contamination which may lead to spoilage and health hazards for workers and the consumer. The choice of industrial cleaning equipment depends on the level of disinfection needed, the sanitizing agent, the size of the area or objects to be treated, and the suitable method of treatment such as sterilization, pasteurization, exposure to ultraviolet light, or chemical fogging.

Disinfection

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

Industrial sterilization processes are employed in different industries to completely eliminate all living microorganisms from the final product. For instance, in food processing, sterilization equipment is used to produce a stable product with a long shelf-life by eradicating harmful bio-contaminants. Instead, in the medical field, sterilization technologies aim to prevent the transmission of microbes to patients by sterilizing all the tools and medical devices that come in contact with the patient. Most sterilization equipment, such as autoclaves, employs high-temperature pressurized steam to destroy bacteria and disinfect surfaces from spores. Other methods include radiation sterilization or using chemicals such as hydrogen peroxide for disinfection.

Sterilization

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

Separating

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 pharmaceutical manufacturing, accurate and efficient capsule filling is crucial, especially when dealing with powders that are difficult to tamp or compact. Challenges such as powder waste, low yield, and downtime due to changeovers need addressing to improve overall equipment effectiveness (OEE).
<h2>Achieve higher yields with efficient capsule filling</h2>
The ZRO 90T by ACG World is a capsule filler designed to ensure higher yields during capsule filling operations. Its patented ZRO technology, based on Zero Relative Motion (ZRM) in the powder-filling station, simplifies the process of filling capsules with sticky, fluffy, hygroscopic, and heat-sensitive powders. The ZRO 90T reduces powder waste and increases yields, achieving up to 90,000 capsules per hour while ensuring dust-free operation. The system supports partial filling capabilities for capsule sizes ranging from 000 to 5, with as low as 25 mg for low-dose APIs. Additionally, it offers simple mechanical changeover within an hour, maximizing productivity and minimizing downtime. The ZRO 90T can handle various fill materials, including powders, pellets, tablets, micro-tablets, capsules, soft gels, and their combinations. It integrates seamlessly with the ACCURA 100% capsule check-weigher for accurate weight verification.

Capsule filler for high-speed, dust-free capsule 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

In the pharmaceutical industry, handling highly potent active pharmaceutical ingredients (HPAPIs) requires advanced containment. These ingredients, often used in oncology and hormonal therapies, pose significant risks to operators and require strict occupational exposure limits (OELs) to ensure safety.
<h2>Fill capsules with potent drugs safely</h2>
The SECUREFILL 6T by ACG World is designed to fill capsules with oncological, hormonal, biopharmaceutical, and antiviral formulations. It complies with occupational exposure band (OEB) up to level 4, protecting operators from exposure to HPAPIs with OELs from 1-10 µg/m³. The system features a monoblock structure of stainless steel SS316L, HEPA filters, glove ports, and rapid transfer ports (RTP). The SECUREFILL 6T ensures efficient wet-in-place cleaning to capture suspended particles, providing safety and simplifying maintenance. It is ideal for small production batches and can process capsules of sizes ranging from 00 to 5 at a maximum speed of 6,000 capsules per hour. Its compatibility with check-weighers, metal detectors, and de-dusters further safeguards against contamination throughout the production line. This makes the SECUREFILL 6T a practical choice for industries handling highly potent and cytotoxic drug formulations.

Containment capsule filling system for highly potent drugs

In pharmaceutical manufacturing, handling highly potent active pharmaceutical ingredients (HPAPIs) such as oncological, hormonal, and antiviral compounds poses significant safety challenges. Ensuring operator safety and product integrity while maintaining high containment standards is critical.
<h2>Fill capsules with high containment and precision</h2>
The SECUREFILL 40T by ACG World is part of the SECUREFILL series, designed for high-level containment in capsule filling. Supporting occupational exposure band (OEB) up to level 4, this system ensures complete containment, avoiding operator contact within OEL range 1-10 µg/m³. It features a monoblock structure of SS316L with HEPA filters, a rapid transfer port (RTP), and glove ports. The accurate dosing mechanisms maintain a negative pressure environment, ensuring precise filling of oncological, hormonal, biopharmaceutical, and antiviral formulations. The integrated wet-in-place system conveniently wets all suspended particles, making cleaning efficient and straightforward. The SECUREFILL 40T can handle various capsule sizes from 00 to 5 at a maximum speed of 40,000 capsules per hour, making it ideal for medium to large production batches. Compatible with additional equipment like check-weighers, metal detectors, and de-dusters, this machine ensures the production of high-quality capsules under safe conditions.

Containment capsule filler for highly potent drugs

In the pharmaceutical industry, producing liquid-filled hard capsules with precision and minimal waste is crucial. Challenges include varying liquid viscosities and the need to fill oxygen-sensitive formulations efficiently.
<h2>Automated filling with nitrogen purging</h2>
The FLUIDOCAP F70 by ACG World is a fully automatic liquid filling system designed for two-piece hard capsules such as ACGcaps™ GL or ACGcaps™ HL. It handles a range of viscosities from 100 to 40,000 cP, ensuring it can fill capsules with pastes, thixotropic solutions, and hot melts. Its output ranges from 20,000 to 70,000 capsules per hour, suitable for medium to large-size batches. The built-in nitrogen or inert gas purging system supports the filling of oxygen-sensitive formulations, and the 'no-capsule-no-fill' sensors significantly reduce waste. Additionally, FLUIDOCAP F70 can also fill pellets, tablets, micro-tablets, capsules, soft gels, and their combinations in liquid, providing versatility in production.

Liquid filling system for hard capsules

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 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

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

In pharmaceutical manufacturing, ensuring accurate and secure sealing of two-piece hard capsules, especially when filled with liquids of varying viscosities, is crucial. Challenges include leakage prevention and consistency in seal integrity, making specialized sealing technology essential.
<h2>Seals hard capsules with precision</h2>
The PROSEAL 70 by ACG World is designed to efficiently seal two-piece hard capsules filled with various contents such as liquids, pellets, tablets, and combinations. What sets the PROSEAL 70 apart is its three-drum loading and orientation system ensuring smooth and efficient capsule loading. It features provision for both manual and automatic gelatine bath replenishment, offering flexibility in operation. The system also includes an option for automatic viscosity control and gelatine recycling, which allows for better in-process control and prevents gelatine wastage. Enhanced drying mechanisms are achieved through two blowers, one for suction and the other for discharge, improving airflow management and ensuring effective drying of capsule seals. The PROSEAL 70 can be integrated with FLUIDOCAP, providing a seamless solution for liquid filling and band sealing.

Capsule band sealer for liquid-filled hard capsules

In pharmaceutical and nutraceutical manufacturing, preventing stoppages in encapsulation lines due to defective empty capsules can enhance productivity significantly. Ensuring a smooth and continuous operation is critical for maintaining high output and quality standards.
<h2>Automates defective capsule sorting and loading</h2>
The Sorter Elevator (SE) by ACG World is an integrative solution designed for automatic encapsulation machines. The SE connects directly to the machine's empty capsule hopper and efficiently sorts defective empty capsules, preventing machine stoppages during the filling process. It features a high throughput—up to 220,000 capsules per hour—ensuring that the encapsulation line operates efficiently. Designed with a compact footprint, the SE maximizes space utilization and integrates seamlessly with other ACG encapsulation machinery to automate the capsule loading process fully. Additionally, it supports both smaller (100,000 capsules/hr) and larger (220,000 capsules/hr) outputs, catering to various production scales.

Capsule sorter elevator for encapsulation processes

In pharmaceutical manufacturing, ensuring the quality and uniformity of filled capsules is critical. Caps and bodies separating from filled capsules can lead to product inconsistencies and potential compliance issues.
<h2>Automatically sorts empty and defective capsules</h2>
The ECS 100 by ACG World is a specialized system designed to automatically sort out empty capsules, loose caps, and loose bodies from the filled capsules generated during the encapsulation process. With a compact design, the ECS 100 can be easily integrated into the capsule filling line. The system operates through a simple sorting mechanism that ensures ease of operation and minimal maintenance. It can process up to 200,000 capsules per hour, thereby improving production efficiency and ensuring only properly filled capsules proceed further along the manufacturing line. This sorter is ideal for pharmaceutical companies looking to enhance their capsule quality control processes.

Empty capsule sorting system for pharmaceutical manufacturing

In capsule production, excessive powder on capsule shells can lead to compromised product quality and operational inefficiencies. Ensuring clean capsule surfaces is crucial to meet stringent pharmaceutical standards and to prevent contamination during packaging and distribution.
<h2>Efficiently remove dust and polish capsules</h2>
The DP De-dusting and Polishing System by ACG World offers a horizontal design that integrates seamlessly with encapsulation lines. Using a rotating brush mechanism, the system efficiently removes excess powder from capsule surfaces in a continuous process. Equipped with an air displacement unit, it ensures complete dust removal from the capsule shells, preventing re-deposition. The system features food-grade certified contact parts, guaranteeing safe handling during operation. Ideal for pharmaceutical and nutraceutical industries, the DP system supports production capacities up to 200,000 capsules per hour, ensuring high throughput and maintaining product integrity.

Capsule de-dusting and polishing system

Industrial cleaning equipment is used to wash or disinfect machinery and the production/warehouse area. It may also be used to sterilize the product, equipment, tools, floor or work surfaces and to purify or clean the product by removing impurities. Choosing a suitable cleaning system depends on the type of product or equipment to be cleaned, the sensitivity of the product to heat, pressure, and chemicals, and the level of sterility desired.

Cleaning

Polishing

The use of several different tools for lifting, de-dusting, and polishing in the pharmaceutical industry can be time-consuming in performing all three steps separately. The users face quality issues like non-uniformity in lifting, griminess in de-dusting, and inappropriate appearance in the production and packaging of products like capsules, tablets, and softgels. To cope with such quality issues, an automated and user-friendly solution would be a good choice for the pharmaceutical industry, saving time and maintaining the product's overall quality.
<h2>Lifting, De-dusting, and Polishing of Tablets through Automation</h2>
HELIX, a machine series of Sensum, is an automated vertical lifter, de-duster, and polisher. Tablets, capsules, and softgel of different shapes and sizes can be used. The machine simultaneously lifts, de-dust, and polishes required tablets, capsules, and softgels. The products material is vertically lifted, de-dusted by constant air supply, and polished gently by a rotational spiral brush. It is user-friendly as the formatting of parts is not required. It has an ergonomic tool-free design with modular parts, which makes it simple and flexible to use in different scenarios and heights. The compact and mobile machine finds its applications in tablet processing or coating, bottle filling, blistering, metal checking, capsule filling, and weighting. It can also provide inline peripherals, containment solutions, and autonomous quality control.

Lifter and De-duster for Tablets

Thermoforming

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.

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Semi-automatic capsule filler

Capsules are a popular method of dosage delivery for a wide range of compounds. For anything other than the smallest of lab-scale production, the manual loading of capsules into trays prior to filling is a time-consuming bottleneck in the process. An automatic or semi-automatic capsule loader can massively increase the throughput and efficiency of your small to medium scale production.
<h2>Automatic and semi-automatic solution for capsule filling tray loading</h2>
The MS 1 from Multigel is an automatic capsule loader designed to complement the MS 6 AUT capsule filler as part of an automatic capsule production system.

Available in full and semi-automatic options, the MS 1 can quickly align and load batches of either 150 or 300 capsules into filling trays. The MS 1 is able to fill a 300-capacity tray in under 40 seconds, offering a throughput of up to 30,000 capsules per hour.

Designed for maximum flexibility, the MS 1 can align, and load capsules sized from 000 to 5. Its footprint is only 410mm x 700mm meaning it can be placed in the most convenient place for workflow to the capsule filler.

Cleaning is swift and straightforward thanks to all product-contacting parts being easily and quickly removable. This reduces time taken in cleaning and maintenance.

Automatic capsule loader

<span style="font-weight: 400;">Softgel (or soft gelatin) capsules are a very popular means of delivering oral doses in the pharmaceutical and food supplements industries in particular. A key stage in the manufacture of high quality softgel capsules is the post-formation drying phase. It’s vital that excess moisture is removed from the gelatin in a controlled manner to maintain the capsule quality and protect the compound within. Tumble drying is the most effective method for this initial drying phase, and a well-designed softgel tumble dryer will yield high quality results in a reduced time, with minimal damage or wastage to the capsules.</span>
<h2>Efficient gelatin capsule tumble dryers for a wide range of production scales</h2>
<span style="font-weight: 400;">The TD5, TD8, TD10 and TD24 tumble dryers from Technophar offer a superior preliminary capsule drying solution for a range of production volume requirements. Every machine in the range is UL or CE certified, with FDA approved material contact parts, and they all fulfil the GMP standards for pharmaceuticals production.  </span><span style="font-weight: 400;">Available in single or double-deck configurations depending on the number of baskets, the TD range have all been designed to offer simple and quick cleanup, easy access for maintenance and inspection, and all employ a lightweight basket design for rapid changeovers.</span>

<span style="font-weight: 400;">Technophar tumble dryers have advanced features including variable speed, high frequency blowers, and automatic capsule transfer. All production parameters are set using a PLC (Programmable Logic Controller) with simple-to-use touch-screen control and monitoring. </span><span style="font-weight: 400;">Built-in heat modules are available as an option on all TD models. The double-deck TD24 model allows for a longer drying time, removing more moisture from the gelatin than single deck models, and thus reducing the time spent in the drying tunnel for the final stage of drying.</span>

Softgel tumble dryer

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

High capacity capsule filler

<span style="font-weight: 400;">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;">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

Whether you want to improve the stability of nutrients, protect an active chemical agent or control the release rate of a given ingredient, you may benefit from a continuous solution that generates reproducible microspheres and is scalable from pilot to production capacities.
<h2>Rapid, uniform and reproducible microsphere formation</h2>
Both the INFINITY Mini and the INFINITY Lab from EmulTech’s Microfluidic Encapsulation System are versatile platforms for rapid uniform and reproducible microsphere formation for encapsulating small molecules, peptides and proteins, with a particle size of 1 μm and up. This system’s unique continuous flow technology provides high reproducibility, which reduces process development costs and eliminates out-of-spec material.

Microencapsulation system for your drug delivery system

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

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

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

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

When encapsulating products at temperatures up to + 80°C, these tend to solidify at an ambient temperature. Capsules containing such products require to be sealed.


<h2>Sealing of hard gelatin capsules after the filling process</h2>
The BD-3000 capsule sealing machine by Dott. Bonapace is an automatic, bench top, capsules sealing machine (by banding the two capsule portions) with an output speed of 3000 capsules per hour. The R&amp;D hard gelatin capsule sealing machine, consists of 4 sections: capsule’s orientation, capsule’s sealing, capsule’s drying, and capsule’s ejection. The weight of the machine is 70 kg with dimensions of 850 x 610 x 510 mm.

R&D hard gelatin capsule sealing machine

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

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

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

Capsule fillers

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

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

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

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

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