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Encapsulation Equipment

capsule-line

capsule line

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

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

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.

Batch

Continuous

Industrial

Pilot

In research and development applications, precise encapsulation of active ingredients or cells requires a solution that can handle a variety of particle sizes and maintain sterility. Challenges include achieving a tight particle size distribution and producing high-quality microcapsules efficiently.
<h2>Produces innovative microbeads and microcapsules</h2>
The Encapsulator B-390 / B-395 from Buchi is designed for the versatile production of microbeads and microcapsules. It supports both open and sterile modes of operation, catering to applications in the pharmaceutical, food, and biotechnology industries. The system allows you to produce particles ranging from 150 μm to 4 mm in size, with a throughput capacity of 1 to 40 mL/min. The precise control over particle size and low-impact conditions ensure high yields and reproducibility. Notable features include a nozzle heater for viscous samples, various nozzle systems for different particle requirements, and an easily calibrated syringe pump for low-loss feed of small sample quantities. The Encapsulator B-395 Pro variant additionally offers material certificates for GMP documentation and comes with a completely autoclavable reaction vessel, making it suitable for integration into GMP-compliant production processes.

Encapsulation equipment for microbeads and microcapsules

Encapsulation

solid

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

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

Dosing

liquid

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

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

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

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

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

In pharmaceutical operations, especially during compression and encapsulation, substantial amounts of waste powder are generated. Efficiently recovering this waste is crucial to prevent material loss, maintain cleaner workplaces, and ensure compliance with regulatory standards.
<h2>Recover up to 99.9% of waste powder</h2>
The Hanningfield Uni-Dust cyclone is a high-efficiency system designed to recover waste powder from pharmaceutical oral solid dosage (OSD) processes such as compression and encapsulation. This equipment enables the capture of waste powder with an impressive efficiency rate of 90 - 99.9%, minimizing material loss and allowing for potential reintroduction into the process. It operates without filters, significantly reducing maintenance needs. Built from GMP-compatible stainless steel, it ensures compliance with regulatory standards. The Uni-Dust cyclone can connect to various process machinery via flexible hoses or stainless steel pipework, and is capable of integrating with ancillary systems like tablet dedusters or capsule polishers. Available in various models with different airflow capacities, it suits multiple industrial requirements.

Waste powder recovery cyclone for pharmaceutical processes

Compression

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

Recovery

Powder

Handling and transferring powders and pellets in pharmaceutical manufacturing often face challenges such as spillage, dusting, and maintaining product integrity. Effective and reliable transfer to capsule-filling machinery is crucial to ensure seamless production and compliance with safety standards.
<h2>Efficiently transfer powders and pellets to encapsulation</h2>
The product conveying system (PCS) by ACG World is designed to automatically transfer powders and pellets to capsule-filling hoppers. Utilizing a vacuum conveyance approach, it ensures no segregation during transfer and maintains the integrity of the formulation. Constructed from stainless steel and food-grade materials, the PCS guarantees product safety and compliance with cGMP standards. The system features a transfer capacity of up to 400 liters per hour, ensuring a quick and consistent supply to the capsule-filling machine. Additionally, the blower is isolated from the filling room, making it suitable for silent operation areas without spillage or dusting.

Automated powder and pellet product conveying system

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

Handling

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

<span style="font-weight: 400;">High output softgel (or soft gelatin) capsule encapsulating machines can operate below maximum efficiency if relying on a traditional tumble dryer and drying tunnel system for the all-important capsule drying cycle. A dedicated continuous drying system dries non-hygroscopic oil fills in a continuous in-line process, and at the end of the drying cycle the capsules are discharged ready for inspection. This completely eliminates the need for drying trays and tunnels, and allows high volume encapsulators to work at full efficiency.</span>
<h2>Complete softgel drying system for high volume oil-filled capsule production</h2>
<span style="font-weight: 400;">The ILDS24 from Technophar is an automated, continuous oil-filled capsule drying system that uses 2 parallel rows of 12 drying units. The drying lines have 3 zones where air is fed at different temperatures and humidity profiles to ensure the most efficient drying process for your softgel capsules. </span><span style="font-weight: 400;">The use of pre-drying tumble dryers and drying tunnels is completely eliminated, meaning that capsules exiting from the ILDS24 are ready for immediate final inspection and packaging, saving time and manual labour.</span>

<span style="font-weight: 400;">The units are fully PLC controlled with touchscreen HMI, allowing simple access to all features including cycle time, basket speed, blower speed, and air parameters. </span><span style="font-weight: 400;">Drying baskets are fabricated from perforated stainless steel sheet, and have side access doors and a large removable end-cover for easy inspection, cleaning and service. A distributor unit feeds both lines alternately with capsules from the encapsulating machine, maximising throughput matched to the encapsulation performance.</span>

Continuous in-line softgel drying system

<span style="font-weight: 400;">When producing high quality softgels its important that the gelatin base is processed and stored correctly. Dedicated gelatin melters and storage tanks ensure your high capacity encapsulation machines have a constant supply of perfect gelatin ribbon for forming into capsules at maximum capacity and with the highest quality results.</span>
<h2>A range of standard and fully automatic gelatin melters and storage tanks</h2>
<span style="font-weight: 400;">Technophar is a leading supplier of gelatin melters. As well as a complete range of commercial-sized standard and automated melters (including load cells, automated evacuation, temperature control, mixing, and PLC with recipe screen) they also supply plug and play melting solutions for lab-scale operations.</span>

<span style="font-weight: 400;">As well as high performance melters, Technophar also offers a range of customer gelatin holding tanks, ranging from 50 litres to 400 litres capacity. Options include single wall tanks as well as double wall tanks with temperature control to maintain perfect conditions during the gelatine ageing and setting phase. Pressurized tanks are also available for higher viscosity melts.</span>

Gelatin melters and tanks

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

<span style="font-weight: 400;">The final stage in high quality softgel (or soft gelatin) capsule production is the capsule polish. This ensures that the capsules are cleaned, and that any oil residue is removed before being placed in consumer packaging. Flexible capsule polishing machines that offer a large capacity can improve your line efficiency by matching the output of your high performance softgel encapsulation machines.</span>
<h2>Manual and automatic capsule polisher with high capacity</h2>
<span style="font-weight: 400;">The CPP Softgel polisher from Technophar is ideal for the final finishing of softgel capsule in both pharmaceuticals and nutraceuticals production. Robust build quality and tried and tested belt and gear drive ensures a long lifespan and minimal downtime.</span>

<span style="font-weight: 400;">The CPP has a tumbler basket that can hold up to 120kg of capsules per load, perfect for high volume capsule production lines. It operates as a self-contained unit, and requires no special electrical connections, allowing it to be used in any situation. Weighing just 500kg, the CPP is fitted with high quality castors that make it portable, perfect for production situations with limited space or where production is not continuous.</span>

<span style="font-weight: 400;">All-stainless steel, fully sealed construction prevents leakage and any subsequent contamination and CPP is designed and built to FDA/GMP requirements.  Simple controls make operation easy, and a visual light stack alerts operators to faults and when cycle is complete. The basket lifting cover is safety interlocked, protecting operators from coming into contact with the rotating basket.</span>

Softgel capsules polisher

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

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

For medium-scale gummy production, maintaining high output while ensuring consistent quality can be challenging. Issues such as production speed and multi-color capabilities are critical considerations for manufacturers aiming to optimize efficiency and product appeal.
<h2>Produce up to 120,000 gummies per hour</h2>
The GT1200 Automatic Gummy Production Equipment by Gummy Technologies is designed for both batch and continuous gummy production. Capable of producing up to 120,000 gummies per hour, it is ideal for medium production runs. The system allows for the creation of gummies in one or two colors, offering versatility in production. With power requirements of 220V/3PH/60HZ or 480V/3PH/60HZ, it fits various industrial settings. The batch system dimensions are 56 feet in length, 8 feet in width, and 9 feet in height, whereas the continuous system is 77 feet long, 15 feet wide, and 11 feet high. Its gross weight is approximately 15,000 kg. These specifications ensure that the GT1200 can handle substantial production loads while maintaining high quality.

Automatic gummy manufacturing system

Batching

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

<span style="font-weight: 400">The molding process is often included in bakery products. Utilizing molding equipment guarantees a uniform shape, weight, and size. The molding machine first gently flattens the dough mix by going through a sheeter, where a series of rollers press the thin piece of dough. The sheet is then cut into the specified shape and, depending on your final product, may be rolled by using a curling chain. After the molding, other ingredients may be added before the products are conveyed for baking or freezing.</span>

Moulding

In laboratory settings, creating precise, small-batch powder samples for feasibility, development, and clinical trials can be challenging. Ensuring high recovery rates and scalable particle properties is essential.
<h2>Produce precise powder samples with minimal material loss</h2>
The GSD-200 GENESIS™ from Freund is a portable, self-contained laboratory spray drying system. It features a drying chamber, atomizing nozzle, cyclone, and exhaust fines filter, all contained within a robust 304 stainless steel exterior and 316L stainless steel product contact parts. The unit can operate in both open and closed-loop systems, with an optional nitrogen inerting upgrade for solvent processing. A key feature is the discovery module, allowing the production of sub-gram samples with almost complete recovery. Additional options include a pressure nozzle for commercial scale representative particles and modular cyclone configurations for optimized processing. The system uses a reliable VFD motor, continuous duty fan, and proven cartridge filter technology to minimize interruptions and maintain longer batch runs. Scalable spray nozzles and integrated process data collection facilitate seamless transition to larger systems.

Laboratory spray dryer for sub-gram powder samples

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 high-volume pharmaceutical manufacturing, the need for machines that can efficiently produce large batches of tablets while ensuring precision and compliance with regulatory standards is critical. The challenge involves managing intensive operations and frequent format changes without compromising quality or productivity.
<h2>Maximize production capacity with flexible tablet press</h2>
The F30p tablet press of the new p Series by Fette Compacting is designed to meet the demands of large batch productions. This double rotary tablet press boasts a maximum output capacity of up to 1.14 million tablets per hour and features advanced energy-saving technology, achieving up to 40% efficiency improvements. The machine's optimized design supports intensive utilization and high yields, while its compatibility with various product requirements makes it adaptable for diverse applications. Equipped with a user-friendly CAN-Bus system and an intuitive interface, the F30p ensures smooth turret changes and format flexibility, reducing downtime and enhancing operational efficiency. Compliance with cGMP and FDA requirements guarantees reliable performance, and batch-to-batch format changes can be completed within 30 minutes, enabling swift transitions in production schedules.

High performance tablet press for large batches

Counting

Pressing

In the confectionery industry, producing licorice and fruit gum with multiple flavors and colors often requires multiple machines and complex setups. This can lead to inconsistent product quality and higher operational costs.
<h2>Produce up to 6 colors and flavors simultaneously</h2>
The Extrufood Diemix® is a specialized system designed to streamline the production of licorice and fruit gum with up to six different colors and flavors using a single extruder. This system begins by splitting the mass from the extruder into equal streams. Each stream undergoes a process where color and flavor are added before passing through a dynamic mixing stage to ensure a homogeneous mix. The Diemix® features a dosing skid to accurately dose each color and flavor, guaranteeing consistency. Its compact design allows it to be easily adapted to various mass types and seamlessly fit into existing production systems with minimal modifications. The Diemix® can be integrated with all Extrufood extruder types, making it possible to produce up to six single-colored licorice products or various combined colored fillings in a single production run. This technology is highly versatile and user-friendly, offering a scalable solution for complex confectionery requirements.

Multi-color and flavor confectionery production system

Blending

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

During the synthesis of radiopharmaceuticals, ensuring operator radioprotection and maintaining sterility and cleanliness are critical challenges. Effective containment of radioactive materials and prevention of contamination are vital for safe and compliant operations.
<h2>Ensure radioprotection and sterility in synthesis processes</h2>
The MIP Series Shielded Cell by Comecer is designed to host automatic modules for the production and research of radioisotopes and radiopharmaceuticals. This solution provides comprehensive radioprotection and decontamination features. The work chamber is sealed, shielded on every side, and kept under negative pressure, ensuring safe working conditions. With options for 75 mm or 100 mm lead shielding and compliance with Class B air quality standards (at rest), the MIP Series accommodates various synthesis modules, including large, complex systems like HPLC. Additionally, the system features an advanced drawing system for vial extraction without chamber opening, further enhancing safety and operational efficiency. The MIP Series includes a touch-screen operator panel for real-time monitoring, stainless steel fluid supply lines, and an array of customizable features such as tele-manipulators and autoclaves. It meets cGMP guidelines, making it suitable for advanced research and routine production.

Shielded cell for radiopharmaceutical synthesis

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

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

Monitoring

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

Manual

In materials and chemistry research laboratories, preparing compound samples requires precision and the ability to apply significant pressure. Researchers often face the challenge of creating uniform pellets under controlled conditions, including oxidizing and inert gas atmospheres.
<h2>Press compound samples with high pressure</h2>
The MP40 Pellet Press from Across International is a laboratory instrument designed to press up to 40 metric tons, ideal for preparing compound samples in research settings. This desktop manual press features a built-in hydraulic pump with an auto-return function, making it suitable for operation in glove-boxes under oxidizing and inert gas atmospheres. Its maximum working space is 6.1x4x6.7 inches, and it is compatible with Across International 4-inch ID round die sets. The hydraulic cylinder has a travel distance of 1 inch, and the press itself has dimensions of 13x8x22 inches, weighing 120 pounds. The device is user-friendly and includes essential accessories, such as hex L-keys and double open-end wrenches. The supplier, Across International, provides various diameter pressing dies at extra cost. This pellet press is commonly used in materials and chemistry research, ensuring precise and consistent sample preparation.

40-ton pellet press for laboratory applications

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

<span style="font-weight: 400;">Softgel (or soft gelatin) capsules are a very popular method for providing oral doses, pharmaceuticals and supplements thanks to their ease of swallowing, lack of taste and tamper-proof nature. When designing new products, new formulations, or experimenting with softgels as a novel form of dosing for existing products, a lab-scale encapsulating solution allows you to test efficiently with the knowledge that results can be scaled up to full production. For small runs of high-value or low-volume product, a small-scale machine can increase efficiency compared to using equipment designed for larger volumes, as well as saving time on changeover.</span>
<h2>Small-scale, high quality softgel encapsulators for lab or small-batch use</h2>
<span style="font-weight: 400;">The SGL107 and SGL207 softgel encapsulators from Technophar offer industry-leading quality for the lab or small batch production environment. The SGL107 can operate at up to 4,500 capsules per hour, and the SGL207 at up to 9,000 capsules per hour. </span><span style="font-weight: 400;">Both models feature the same high-quality components and robust build-quality. Rather than relying on mechanical gearing, both machines feature servo motors and electronic gearing to increase reliability and reduce downtime. Programmable Logic Controllers (PLC) with touchscreen user interface gives quick access to and control over all the production parameters.</span>

<span style="font-weight: 400;">For maximum durability, the SGL107 and SGL207 are built around a solid aluminium frame design, with stainless steel outer covers. These can be specified to meet GMP/FDA requirements where required for pharmaceutical use. This means that the machines are easy to clean and maintain and will not corrode.</span>

<span style="font-weight: 400;">Fitted on castors for easy movement if required, the SGL107 and 207 are fully self-contained, with control and electrical panels within the machine, ideal for non-permanent or semi-permanent applications, as well as permanent small-batch production. </span><span style="font-weight: 400;">Each machine can produce oval or oblong capsules, with the SGL107 having a single dosing plunger, and the SGL207 having two dosing plungers, allowing you to choose the best option to fit your requirements.</span>

Laboratory scale soft gelatin capsule machine

<span style="font-weight: 400;">Soft gelatin (or softgel) capsules have become a popular mode of oral liquid dosing for the pharmaceutical and food supplements industries. Their obvious benefits include the lack of any taste, their tamper-proof enclosure, and the ease with which they can be swallowed compared to tablets and capsules. For full-scale manufacturing, a high quality, reliable, accurate and fast softgel filling solution is required. A machine range that offers a variety of throughput and speed options allows tailoring to your exact production requirements.</span>
<h2>Full-scale, high quality softgel encapsulators for a range of production volumes</h2>
<span style="font-weight: 400;">The SGM407, SGM610i, and SGM612i softgel encapsulators from Technophar offer industry-leading quality and reliability for the full-scale production of oval or oblong filled softgel capsules. With maximum output capacities ranging from 172,800 capsules per hour up to a class-leading 506,880 per hour, the SGM range has the ability to meet your exact production needs.</span>

<span style="font-weight: 400;">All SGM models feature the same top-quality systems and components and feature superb build-quality for operational reliability and longevity. The SGM range has avoided the need to use less reliable mechanical gearing, and has adopted servo motors and electronic gearing in all critical components to decrease downtime associated with preventative maintenance and breakdown.</span>

<span style="font-weight: 400;">The SGM softgel filling range are all built on solid aluminium frames, and offer a range of stainless steel outer covers to your requirements, including GMP/FDA specification if required. The all-stainless cladding ensures that SGM filling machine are easy to clean and sanitise and are totally corrosion-resistant for a long lifespan.</span>

<span style="font-weight: 400;">The SGM407 features a separate Programmable Logic Controller (PLC) and electrical cabinet, while the other models are fully integrated. All feature a touchscreen user interface which gives quick access to, and full control over, all the production parameters. </span><span style="font-weight: 400;">Each machine can produce oval or oblong capsules, and you can select the best option to fit your production throughput requirements.</span>

Automatic soft gelatin capsule machines

<span style="font-weight: 400;">By employing a weight sorter that is fully flexible and able to handle a wide variety of dose shapes and sizes you can benefit from reduced equipment cost and improved production. Such flexibility without the requirement to change machine parts is now available for large scale production facilities.</span>
<h2>Easy to use, fully flexible weight sorter for large scale production</h2>
<span style="font-weight: 400;">The SADE SP440 from CI Precision is a highly accurate, easy to operate and fully flexible dosage weight sorter for use in larger-scale production environments. Featuring a single 150l hopper and 4 weighing channels for bulk operations at up to 22,000 units per hour and an easy-to-use operator interface, the SADE SP440 is accurate to within +/- 2mg.</span>

<span style="font-weight: 400;">Designed with flexibility in mind, the SADE SP440 can handle a wide range of tablets and capsules, switching between them with no requirement for changing physical parts to accommodate different dose types. The SADE is able to weigh tablets up to 20mm x 24mm, and capsules from 5 through to 00 size (larger sizes may be accommodated). The machine is also able to be quickly and easily dismantled for cleaning and sanitizing.</span>

<span style="font-weight: 400;">The unit has the ability to reclaim “good” product from a weight-rejected batch, saving valuable product and producing less waste. The unit records all sort operations and can print reports direct to a printer or send to a PC.</span>

High capacity weight sorter for tablets &amp; capsules

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

Weighing

<span style="font-weight: 400;">The production of pharmaceutical capsules requires that individual doses are checked for accuracy. In a production environment this also needs to be done at speed. Fast throughput and ease of use are important in a production scale checkweigher.</span>
<h2>High accuracy, easy-to-use weight checkers for a range of production scales</h2>
<span style="font-weight: 400;">The Sejong Pharmatech iW Series of production weight checkers have been specifically designed to give the highest accuracy whilst maximising throughput and simplifying operation and maintenance.</span>

<span style="font-weight: 400;">Available in 4 variants, the iW series is capable of checking 10,000, 60,000, 120,000 or 180,000 units per hour to suit your exact requirements.</span>

<span style="font-weight: 400;">The highly accurate weight cell used offers accuracy of +/-2mg whilst operating at these speeds, and the simple to use touchscreen display provides instant graphical feedback on the performance of the unit. The control system is fully 21CFR part 11 compliant for record-keeping and monitoring.</span>

<span style="font-weight: 400;">Able to handle a range of capsule sizes from #000 to #5, the machine has two output paths, one for pass, one for reject. Optional extras include air conveyor to transport capsules from the pass chute to storage container.</span>

<span style="font-weight: 400;">The machines are top loaded for convenience and feature built-in castors to allow easy movement of location or to access parts of the machine for maintenance and inspection.</span>

Capsule checkweigher

<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

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

<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

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

Laboratory capsule filler for liquid solutions

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

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

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

Fish oil was a folk remedy long before scientists identified the nutritional value of essential fatty acids. But Omega 3 processing has come a long way since the days of raw fish parts fermenting in a barrel. In fact, new supplement formulations of polyunsaturated fatty acids (PUFAs) may not use fish at all.

Omega 3 oil

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

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

Suppositories

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