Learn the Art of Capsule Filling Process using Different Filling Machines

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1 Learn the Art of Capsule Filling Process using Different Filling Machines

Learn the Art of Capsule Filling Process using Different Filling Machines

Filling capsules is a vital process in the pharmaceutical and nutraceutical industries. Production volumes, accuracy requirements, and the type of material are some of the determining factors in deciding the filling machine to use. In this guide, we will take a look at a step-by-step process through which each capsule filler works.

Capsule Filling Process using Manual Capsule Filler

A Flow Chart of Filling of Capsules and Its Packaging Aspects
A Flow Chart of the Filling of Capsules and Its Packaging Aspects

Normally a hand-operated machine is required for filling capsules of low-capacity production or brand product start-ups having small production capacity. In the steps below, you find a guide to help you operate this machine.

Manual Capsule Filling Machine
Manual Capsule Filling Machine

Step 1: Culminate the Working Space.

To prevent such problems as contamination or impurities in the output product, the workplace must be well disinfected. Disinfectants are responsible for capsules’ uncompromised quality and the universality of the dosage.

Step 2: Assemble the manual Capsule Filler

Collect all the elements needed for the capsule-filling machine module as part of the human capsule production. A sample machine consists of the machine base, capsule sheet, body sheet, tamper, and any necessary accessories.

Step 3: Prepare the Capsules

Make the capsules apart, that is its cap and its body parts. Be sure to check if the capsules are completely dry, clean, and not in any way damaged.

Step 4: Prepare the Filling Materials

Weigh the appropriate amount of powdered or granulated material using weights or some measuring device. Ensure that the material is of the correct consistency for filling capsules. Also, the material must not contain clumps or lumps.

Step 5: Place the Base Sheet

Lay the filling machine’s base on a table so that it can be leveled and loaded for the filling operation. Usually, the hole’s diameter on the base plate is similar to that of the capsules that you intend to produce.

Step 6: Position the Body Sheet

Make sure you place the body sheet on the top of the base sheet very gently, facing the right direction. We will put the apertures in the base sheet where the ones in the body sheet were.

Step 7: Fill the Body Sheet

Using a spatula or a suitable alternative, fill the holes of the body sheet with the insert material. Check to ensure that each hole is filled to the very top with the filling product.

Step 8: Spread the Material

Using your fingers, distribute the material evenly on the body sheet. As you spread the product allow the leftover to drop through the holes of the base sheet below.

Step 9: Join the Capsules

Carefully lay the cap sheet on top of the body to match up to the holes in the body sheet.

Step 10: Press and Lock

Depress the cap sheet of the capsules with considerable force to make sure that the capsules will be locked. Now this step unites the capsule halves at the joint areas of the cap and body.

Step 11: Remove Excess Material

Use the scraper or spatula to remove all extra filling material by scraping it from the cap sheet exterior.

Step 12: Remove the Capsules

Lift the cap sheet gently to expose the filled capsules. Carefully lift off filled capsules from the main sheet, keeping them intact.

Step 13: Cap and Store

Finally, close all unified capsules using the required technique. Place the filled capsules into a clean and dry container or packaging keeping in mind to label them for proper identification.

Step 14: Clean and Maintain

Remove and clean capsule filling machine components according to manufacturer’s instructions as soon as use is complete. It thus prevents cross-contamination and its life span is extended.

Filling Capsules with a Semi-automatic Capsule Filling Machine

The capability of a semi-automatic capsule filler machine is higher than that of a manual filling machine. Here is the guide on how to operate a semi-automatic capsule filler.

Step 1: Get the Work Space Ready

Keep the work site safe, disinfected, and contaminant-free to avoid impurities in the product. It ensures the unimpaired quality and consistency of the capsules.

Step 2: Assemble the Semi-automatic Capsule Filler

Put together all the components for the capsule-filling machine module. Such components include the bottom, the cap sheet, the body sheet, the tamper, and any auxiliaries of this machine.

Step 3: Prepare the Capsules

Separate the capsules into cap and body parts. Make sure the capsules are clean, dry, and undamaged before the filling process begins.

Step 4: Get Ready for the Product to be Filled

Weigh the appropriate amount of powdered or granulated material using weights or some measuring device. Ensure that the material is of the correct consistency for filling capsules. Also, the material must not contain clumps or lumps.

Step 5: Place the Base Sheet

Lay the base pan of the capsule-filling machine on a flat surface. The base plate is typically perforated with holes having a size consistent with that of the capsules being used.

Step 6: Position the Body Sheet

Very carefully, place the body sheet on the top of the base sheet. This is to ensure that the holes in the base sheet align with the ones on the body sheet.

Step 7: Fill the Body Sheet

Using a spatula or a suitable alternative, fill the holes of the body sheet with the insert material. Check to ensure that each hole is filled to the very top with the filling product.

Step 8: Spread and Level

Use a spreader or scrap to distribute the filling material evenly across the capsule bodies. This is to ensure they are filled to the correct level.

Step 9: Place the Capsule Caps

After the capsule bodies are filled, the caps put on the capsule. See that they are seated in the right position.

Step 10: Press and Seal

Start the machine to imprint and affix caps to the tube of filled capsules. The tool will use force to ensure a good seal.

Step 11: Remove the Filled Capsules

Handle the capsules that you took out of the machine’s output tray or capsule plate. Be gentle with them in order not to damage the capsules.

Step 12: Inspect and Quality Check

Inspect the filled capsules for any defects which include incomplete filling or damaged capsules. Take out all the capsules with errors from the batch.

Step 13: Cap and Store

When all modules have been filled and examined, cap using the proper method or instrument. Put the filled capsules into clean, dry containers or packaging that is labeled accordingly.

Step 14: Clean and Maintain

Then, after use, completely dismantle and clean all semi-automatic capsule filling machine components as instructed by the manufacturer. Regular maintenance is vital for avoiding cross-contamination and for the long life of the machine.

Capsule Filling with Fully Automatic Capsule Filler

A fully-automatic capsule filler is faster and can handle all the filling as well as the sealing in one production line. It is therefore encouraged for large-scale production. Here is the procedure for how you can manage this machine.

Fully Automatic Capsule Filling Machine
Fully Automatic Capsule Filling Machine

Step 1: Prepare Work Space

Make sure that the working area is tidy, disinfected, and free of any contaminants. The sterility of the atmosphere is the main concern in producing quality and safe products.

Step 2: Assemble and fix the Fully Automatic Capsule Filler.

Collect the automated capsule filler system that consists of a machine, a hopper that dispenses filling material capsule magazines, and other accessories. Take the manufacturer’s instructions as a trace when setting up an automatic capsule filler. Normally, it is needed to update machine settings, fill capsule magazines, and adjust filling units.

Step 3: Prepare the Capsules

Divide an empty capsule into two halves – caps and bodies. Validate that the materials are not dirty, damaged or wet.

Step 4: Enlist the Filling Material

Determine the precise weight of the powdered or granulated material by employing either a scale or some other measuring device. Inspect the material integrity as well as impurities.

Step 6: Cargo the Capsules

Drop the empty capsule bodies into the loading tray and the capsule magazines. Ensure that they have the right position and the designated places.

Step 7: Pack the Capsules

Fill the hopper of the machine with the prepared filling material. The machine will dispense the needed amount of material into each capsule shell automatically.

Step 8: Spread the Material

The filling stations will be automated and filled uniformly all over the capsule compartments. It is to make sure that the proper filling up is done.

Step 9: Join the Capsules

Once the machine is filled with the bodies of capsules the caps will be automatically put on the filled bodies by the machine. Ensure that they are well positioned and placed correctly.

Step 10: Check and Test

The device may have inside sensors or cameras for completeness analysis of the whole capsule, for example, broken capsules and incomplete filling. Throw away the batch whose capsule is non-conforming.

Step 11: Capsule the Seals

The integrated fully automatic capsule filler will also guarantee the packed capsules have a very tight and secure closure.

Step 12: Assemble the filled Capsules

This machine will place the filled and sealed capsules onto a tray or a conveyor belt. Collect the completed capsules and proceed to the next stage of the manufacturing process.

Step 13: Sanitize and Clean

Once you have finished, make sure you clean the capsule filler machine the way the manufacturer recommended. Regular maintenance and cleaning become very vital for attaining productivity capacity at the highest level and also avoiding contamination.

Conclusion

Generally, the art of capsule filling relies on the combination of technical know-how, operational skills, as well as attention to detail. These three are applicable irrespective of the type of filling machines. The unique characteristics of each machine are also accompanied by relative advantages and considerations.

Whatever type of device that ought to be used varies with factors like production volume, formulation characteristics, and budget constraints. Capsule filling is an effective process only when there is a perfect blend of art and applied sciences. Here is to ensure consistency in quality and to comply with the requirements.

More resources:

Types of Capsule Filling Machine – Source: LOM

Manual Capsule Filling Machine – Source: LOM

Capsule Filler – Source: WIKIPEDIA

How to Clean Capsule Filler Machine – Source: LOM

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