Automatic capsule filling machines have become essential in large-scale nutraceutical and pharmaceutical capsule manufacturing. These capsule filler machines, noted for their efficiency and accuracy, can automatically fill empty hard gelatin capsules with powders, granules, and pellets, ideal for medication capsule production at pharma enterprises. Equipment from China is renowned for its high cost-effectiveness, continuous device upgrading, and precision, stability that meet cGMP standards.
Capsule powder filling machines typically have 3 main categories:
Manual capsule fillers are handheld devices designed to separate, fill, and rejoin empty plant-based or gelatin capsules with powdery substance, primarily used for small-scale, personal production purposes with limited capsule filling efficiency.
A semi automatic capsule filling machine is a hybrid model that enjoys auto capsule filling yet still relies on manual operation. It requires an operator to perform steps such as separating gel capsule shells, compacting powder, and locking filled capsules, while stages like capsule dispensing and capsule filling are automatically accomplished.
An automatic capsule machine is capable of performing entire capsule filling processes, including empty gelatin capsule and ingredient loading, capsule dispensing, capsule separation, filling capsules with powder, waste rejection, capsule locking, and locked capsule output, in an automated way with minimal manual intervention. In other words, with a few touches on a screen, you can create a huge number of filled capsules.
an automatic capsule filling machine
In practical cases, automatic capsule filling machines are indispensable in mass pharmaceutical manufacturing, and here we focus on auto capsule filling characteristics.
Before purchasing your hard capsule filling machine automatic, some considerations need your attention:
2.1 Capsule Size Application: An auto encapsulator machine should be able to handle different capsule sizes ranging from 000 to 5, suitable for capsule manufacturers to change over product batches.
2.2 Production Capacity: The output of different models varies a lot. For example, the capacity of capsule filling machine njp 1200 is 3 times higher than that of an njp 400C. You need to select a capsulator machine based on your production. Commonly used auto models own the capacity of filling capsules from 18,000 to 85,000 pieces/hour.
2.3 Accuracy: As powder dispensing accuracy is closely related to capsule weight consistency, therapeutic effects of medication, and patient safety, the accuracy of measuring and filling systems is critical. In the international pharmaceutical industry, the precision of capsule fill volume is regulated by legal standards; for example, the relative standard deviation (RSD) of fill volume shall be less than 6%.
2.4 Machine Material: A modern pharmaceutical capsule machine must adopt stainless steel as the material for its construction to ensure equipment stability and resistance to corrosion, heat, and collision. Especially, parts in contact with raw pharmaceutical ingredients must be made from stainless steel 316.
2.5 Ease of Maintenance: Suppose that you need to produce different types of capsule, tooling changeover and component cleaning are inevitable. A capsules machine should include modular design for quick mold change and easy maintenance.
The selection of an appropriate automatic capsule encapsulation machine is primarily determined by several key attributes, which influence both operational efficiency and capsule quality. Critical considerations are the filling accuracy and construction material of the machine. In addition, automatic gelatin capsule machines of top quality possess some common advantages to ensure high performance. Let’s have an in-depth exploration into these advantages.
Compared to conventional capsule fillers, best capsule filling machines have much better performance due to their non-negotiable premium mechanisms and components. For instance, a conventional automatic capsule filler impresses users by its high speed, but users form long-term trust in reliable fully automatic capsule filling machines produced by reputable capsule filler manufacturers, such as Syntegon, Romaco, and Rich Packing, according to their continuous, stable operation with high efficiency.
What makes a top-quality gelatin capsule filling machine? With over 20 years experience in developing njp series capsule filling models, we hereby explore their superior advantages.
Precision filling is the cornerstone of pharmaceutical capsule filling, directly determining capsule weight uniformity, batch qualification, and drug dosage safety. Top-tiered automatic capsule filling machine fillers achieve fill weight accuracy through advanced engineering and high-precision hardware such as:
●High-precision Indexing System: Utilizing a German-manufactured Zeiss optical dividing head, the system ensures each processing station rotates with flawless angular consistency, eliminating capsule mold and filling rod concentricity deviations in the dosing disc. The single-piece machined indexing shaft further guarantees alignment, contributing to a low fill weight error of ≤3%.
●Built-in Cams: These automatic capsule making machines employ built-in, dual-face internal cams. This design connects two oscillating levers to inner cam grooves, distributing force evenly during operation. This eliminates the vibration and instability common in external, single-face cams, providing a rock-solid foundation for the entire filling mechanism.
Therefore, the synergy of a flawless indexing system and a vibration-dampening cam mechanism transforms mechanical action into reliable precision, enabling every capsule to meet strict specified fill weight.
While high hourly output is a common benchmark for auto commercial capsule filling machines, true industrial excellence is measured by the capability for long-hour stable operation. Sustaining speeds of filling tens of thousands of capsules per hour over extended 12+ hour shifts is the ultimate test, separating standard capsuling machines from top-tier capsule makers.
This encapsulation stability is the result of a holistic engineering philosophy focusing on durability and contamination control that include:
●High-precision Cam Indexer: 100DS precision cam indexers adopted by capsule filler machine manufacturers such as Rich Packing provide unparalleled motion control and structural integrity, eliminating frequent failures and downtime associated with inferior 83DS indexers.
●Turret Sealing Technology: The main turret is equipped with silicone sealing rings that prevent powder ingress, avoiding mid-operation jams caused by powder blockage.
●Advanced Surface Engineering: Micro-electron polishing of fill rods, capsule mold bores, and dosing discs ensures optimal powder flowability. This critical treatment prevents adhesion and buildup of fine, sticky, or hygroscopic powders, thereby preventing machine stoppage caused by powder accumulation.
Beyond specifics above, a top-tier cap filling machine integrates intelligent thermal management systems, vibration-damping structures, and real-time monitoring sensors. These elements work in concert to guarantee that stability is a predictable constant in high-volume pharmaceutical manufacturing.
Of all challenges in pharmaceutical capsule produciton, controlling powder leakage during high-speed capsule filling is a critical one that impacts capsule filling stability. Imagine that your gel cap machine is packed with residual powder, how can you maintain hygiene pharmaceutical manufacturing and prevent powder buildup that causes component jam?
Premium automatic capsule filling machines tackle this issue through a three-pronged strategy focusing on precision engineering, powder conditioning, and innovative sealing.
●High-precision Tooling: Molds including upper and lower capsule mold holes, dosing discs, and tamping pins are machined to micrometer tolerances, creating a near-perfect seal with capsule bodies. This precision machining minimizes microscopic gaps through which fine powder could escape due to centrifugal force.
●Intelligent Powder Conditioning: The automatic encapsulating njp utilizes a tamping station that gently pre-compacts powder within capsule bodies after filling capsules. This compacting stage increases powder cohesive density, reducing the possibility of becoming airborne from tooling vibration or rapid turret rotation.
●Active Containment: Advanced capsule filler filling machines incorporate localized vacuum extraction ports at potential powder leakage points, such as those around the dosing disc or the capsule locking station. These ports extract away any stray powder. Furthermore, this mechanical design often includes covers, air curtains, or positive pressure zones to contain and redirect airflow, preventing air from fluidizing and dispersing powder within capsule molds.
By synergizing these mechanisms from precision tooling to minimize gaps, controlled tamping to stabilize powder, to active devices to manage airflow, superb capsules filling machines achieve ideal powder containment, minimizing cross-contamination and maintaining a clean production environment.
Preventing internal component collisions is critical for operational safety and equipment longevity. In conventional capsule makers, a primary cause of such impacts is the scraping and breakage of capsules due to imprecise capsule mold alignment generating debris that jams mechanisms. In terms of the root cause, the insufficient precision of the indexing box results in misalignment of capsule mold concentricity.
High-caliber industrial capsule filling machines combat these issues via robust engineering:
●Precision Mold Engineering: Molds are manufactured with fine-tolerance machining to ensure perfect concentricity between upper and lower capsule molds, eliminating capsule scrapage and the resulting obstructive debris.
●Surface Polishing Treatment: Important surfaces, including fill rods and capsule mold bores, have undergone electropolishing to a mirror finish in an effort to improve powder flow and thereby prevent powder buildup. The result is smooth component operation can be ensured.
●Special Coating: For challenging powder formulations, optional specialized coatings, such as Teflon, provide an ultra-slick, non-stick barrier, virtually eliminating adhesion-related jams.
A key design to keep continuous capsule production is the straightforward daily maintenance which directly upholds stable productivity. This is primarily achieved through a modular architecture.
easily disassembled powder fill rods
●Modular-designed Components: Parts such as fill rod modules are engineered for rapid disassembly without specialized tools, allowing for quick cleaning during capsule batch changes and drastically minimizing downtime.
●Self-lubricating Bearings: Further simplifying upkeep, automatic capsule making machines incorporate maintenance-friendly components. For instance, the use of self-lubricating polymer bearings in the turret eliminates the need for manual greasing.
●Intelligent Lubrication System: This system applies automated, closed-loop lubrication that delivers precise amounts of lubricant to critical moving parts like cams at scheduled interval. This automation removes risks of human error—both insufficient lubrication that causes cam wear and excessive oiling that adds contamination. Consequently, planned maintenance becomes predictable, ensuring continuous and hygienic capsule production.
Ordinary automatic capsules filling machines, especially those with exposed external cams suffer from structural instability and obvious noise. The inevitable slight displacements during high-speed operation cause unstable contact with followers, generating impact noise that harms workforce satisfaction and regulatory compliance.
Best capsule machines address this noise issue by adopting integrally-molded internal cams, precision-finished via CNC machining. This seamless design ensures stable transmission component movement, containing operational noise below 65 dB for a safer, more compliant environment.
Machine advantages mentioned above should be taken into review when you are selecting your medication or supplement capsule filler from China. In terms of specific model types, we offer 5 automatic pill capsule fillers that integrates all benefits above for your consideration.
As automatic capsule making machines, these 5 encapsulators are all capable of filling capsules with powder, granules, and pellets, and they can handle capsules with capsule sizes ranging from 000 to 5, automatically and continuously completing production processes of capsule dispensing, capsule separation, filling capsules with raw ingredient, unqualified capsule rejection, capsule locking, and finished capsule discharge.
Same to its peers such as the NJP 1200 capsule filling machine and njp-3800, NJP-400C features precise dosing, stable operation, and a dust-free environment, complying with cGMP requirements. Its max output reaches 24,000 capsules/hour.
The NJP 400 capsule filler machine is engineered for smooth encapsulation, particularly with challenging powders. Its innovative pneumatic powder feed system ensures superior filling accuracy even for cohesive, poor-flowing substances. In addition, its turret is equipped with silicone rubber seals that prevents powder intrusion, eliminating contamination and mechanical blockage.
Designed for easy operation and maintenance, the njp400 features PTFE self-lubricating bearings on its dual horizontal turret shafts, requiring no manual lubrication. Moreover, filling rod holders utilize a pull-out slot design, allowing for quick changes of various rod modules. This equipment is an ideal choice for small to medium-scale production of pharmaceuticals, traditional medicines, and health supplements.
NJP-1500D automatic capsule filler achieves a maximum production capacity of 90,000 pieces/hour, suited for mass production of pharmaceutical and nutraceutical capsules. It represents one of the most popular commercial capsule filling machine in China.
This model is designed for high performance, reliability, and compliance with cGMP standards. Its maintenance is simplified by an intelligent lubrication system from US Bijur that automatically greases transmission mechanisms, ensuring smooth operation. Next, the integral, seamlessly crafted CNC cam minimizes noise during high-speed encapsulating processes, while molds with a slide-in slot quick-release design realize a complete fill rod changeover in under 15 minutes. Furthermore, operational stability and longevity are guaranteed by the integration of globally renowned electric parts, including a Siemens PLC system and human-machine interface, Schneider relays and contactors, an Omron frequency converter, and a Becker vacuum pump.
Reaching a max output of 156,000 capsules per hour, NJP-2600D owns a higher encapsulation efficiency compared to NJP-1500D machine of filling capsules.
This capsule maker machine filling is engineered for high precision and efficiency. Its filling mechanism utilizes three-dimensional adjustment to make sure of even force distribution on the dosing disc, enabling accurate dosage regulation. In another aspect, an integrated powder recovery system achieves 100% powder reutilization, enhancing economic benefits. To address challenges with poor-flowing powders, critical components like fill rods and capsule mold holes undergo electronic polishing and are treated with a Teflon coating, preventing powder from sticking to surfaces. Moreover, molds are manufactured with perfect concentricity and zero deviation, which guarantees capsules are neither scratched nor damaged during turret rotation. All these designs ensure the equipment's continuous and stable running.
This model owns a maximum output of 468,000 capsules per hour, entitling it to a more powerful machine for making capsules in large-scale pharmaceutical manufacturing of medication capsules or dietary supplement capsules.
Based on provided description above, the NJP-3800 capsule filling machine shares a similar scientific design philosophy with its predecessor models. It adheres to a structured and modular concept, ensuring simple operation and extremely low failure rates for high-volume capsule manufacturing.
What’s more, this auto capsule filling is equipped with a pneumatic mold cleaning system by using compressed air. This feature actively maintains the cleanliness of both upper and lower molds, crucial for enhancing final capsule quality and long-term equipment stability by addressing contamination-related issues.
The 4 machine models mention above are fully automatic ones, but what about producing capsules in a small-scale way that still demands some automatic operations? Here, we discuss a semi-auto capsule making model.
With automatic capsule dispensing, capsule filling, and filled capsule output, the CGNT-209 semi-auto gelatin capsule machine requires manual working on capsule separation, powder tamping, and capsule sealing. Despite manual elements, the CGNT-209 capsules machine can produce 40,000 capsules/hour at its highest speed.
Different from conventional semi auto equipment, this encapsulator machine represents an advanced design that enhances operational efficiency and precision. Its key innovation is a dual-row capsule feeding device, which doubles the output compared to single-row fillers. The efficiency is supported by an integrated electro-mechanical and pneumatic control system governing the three core stations—capsule feeding, filling, and locking. This integration ensures smooth coordination between each step, increasing the filling speed. Furthermore, dosing accuracy is managed by controlling the powder feed rate and the mold movement speed, ensuring fill weight error is maintained within a 3% margin.
There are multiple advantages of njp series capsule filling equipment that are not covered by this article. In future encapsulating practice, you can try to contact experienced capsule filler machine professionals for user guidance and technical support.
Top 5 automatic capsule filling machines from China, such as the NJP series, excel by combining precision filling, stable long-term operation, and continuous regulatory compliance. There is a trend that increasingly more capsuling machines in China feature access control, multi-tiered password management, audit trail, and e-signature, designed for offering reliable performance that meets stringent international pharmaceutical production requirements. If you need to choose capsule filler machines, try giving your attention to Chinese suppliers.
Электронное письмо : manager@richpacking.cn
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