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capsule-filler

capsule filler

Capsule manufacturing spans a series of stages until your finished products can be shipped out. Dosage systems and sorters ensure that the capsule filler machine is fed with the right formula at all times. In the case of gel-filled capsules, you would need gelatin melters that keep the mixture ready for use. Depending on their type, capsules are then dried, de-dusted, and polished using dedicated encapsulation equipment and conveyed to a final weight and quality check. Lastly, you may opt for a sleeve label to seal the package and safeguard its integrity to consumers.

Encapsulation

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.

Batch

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&amp;D automatic capsule filler

Dosing systems include hoppers, feeders, filling machines, and checkweighers. The selection of suitable dosing equipment depends on the need to dose by quantity, the size of each dose, and the desired dosing rate. The physical form of the material, health and safety requirements and the container to be filled are also important considerations. Dosing systems are used for filling containers in the pharmaceutical industry and for accurate dosing of ingredients in the food and chemical industries. Discuss your dosing challenge with us to receive advice on the most suitable solution for your application.

Dosing

Industrial filling equipment solutions are used to package a measured mass or volume of a product, at the end of a production line, into a packaging container suitable for the product. The choice of filling system or filling line depends on the physical state of the product, the packaging container of choice, the desired mass or volume per container, the required production volume, and considerations of sterilization and safety.

Filling

Packaging 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. Choosing the best packaging solution depends on the nature of the product, its end-use, and your production process.

Packing

liquid

solid

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&amp;D semi-automatic capsule filler

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

R&amp;D capsule orientater

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&amp;D hard gelatin capsule sealing machine

Continuous

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

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

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

High-yield capsule filler

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

Automatic capsule filler

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

Contained capsule filler

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

Automatic laboratory capsule filler

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

Automatic capsule filler for liquid solutions

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

Laboratory capsule filler for liquid solutions

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

<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

Separation process to separate components of a liquid mixture, for recovering dissolved solids from liquids. 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 are widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high purity chemicals.

Separation

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

Scale up capsule filler

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

High capacity capsule filler

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

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

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

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

Cleaning equipment is used to wash or disinfect machinery and the production area. It may also be used to sterilize the product, equipment, tools, 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

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable 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 systems are used in the food, pharmaceutical, chemical, biomass, and mineral industries to transport bulk powders, granules, and grains for processing and filling.

Conveying

Capsule fillers

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

Softgel capsules

The 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

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 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

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Capsule fillers

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