How To Use Capsule Filling Machine?

A capsule-filling machine plays an integral role in the modern pharmaceutical and supplements industry. You can use this machine to fill material in capsules.

In this guide, you are going to learn how a capsule filler machine works:

Basic Parts of a Capsule Filler Machine

Parts of Manual Capsule Filling Machine
Parts of Manual Capsule Filling Machine
Parts of Automatic Capsule Filling Machine
Parts of Automatic Capsule Filling Machine

Hopper: A hopper is the place where you feed the raw material, which mostly comes in powder form.

Filling tray or plate: This is where you keep the empty capsules.

Spreader: The spreader plays a crucial role in spreading the powder evenly on the filling tray.

Tamper: The tamper forces the powder on the capsules, ensuring that the capsules are full.

Capsule holder: It is the role of the capsule holder to fix the capsules such that they are not free to move.

Ejection system: It spits the capsules out when done filling.

Powder dispenser: The capsule filling system relies on powder dispensing. This ensures proper and weighed powder dispensing.

Capsule orientation mechanism: This method ensures proper orientation of capsule position on time for effective filling.

Sealing mechanism: The sealing mechanism puts a cap on capsules to ensure the contents stay inside.

Control panel or interface: The control panel aids you in manipulating settings and tracking the efficiency of the device. Likewise, you can also detect any problems that may occur while operating.

Frame or chassis: The frame is a structural member that carries the machine loads. It maintains the machine in the right position and offers higher stability.

Step-by-Step Guide to Filling Capsules

Sanitizing and Cleaning

Clean and sanitize the whole machine right before the filling operation. To make sure that capsules are free from contaminants, foreign substances, and other impurities. Employ sanitizing and cleaning activities using standard sanitizers and cleaners.

Capsule Size Selection

Choose a capsule size that satisfies your product requirements and is in terms of the filling device. Measure the dosing volumes against the size of the capsule. Keep in mind that the filling material aligns with the capsule type you are using.

Filling Material Preparation

Prepare the material according to compositional data. Verify if the powdered material exhibits good breakage and particle flow properties. With that, you will have it loaded quickly and easily into the capsules.

Adjustment of the Machine Parameters

Set the machine for the filling material and capsule dimensions. Adjust optional settings that include speed, force, and product ejection.

Filling Tray Installation

Place the lid or capsule dish under the filling container. Find out whether the tray is in a balanced and level pitch.

Illustrating the Working of Capsule Filling Machine
Illustrating the Working of Capsule Filling Machine

Adjust Tamper and Spreader

Correlate the drum’s rotation and the tamper to manage the dispersion and compaction. This will help you maximize productivity and machine efficiency.

Fixing Capsule Holder

Place the capsule holder on the device. The right placing of the holder eliminates the risk of misalignment or jamming of the capsules.

Filling Material Loading In Hopper

Place the weighed mass into the filling machine’s hopper. Make sure that the hopper has always been keeping enough to avoid early termination of the operation.

Filling Process Initiation

Begin filling according to the operations manual for specific devices. Run the machine for the capsules you want to fill with the material.

Filling Speed Adjustment

Tweak the filling speed and adjust it to gain both precision and efficiency. One should check whether the faster filling is suitable for some formulations or productions. Please note it does not decrease the quality or dosage homogeneity.

Filling Process Monitoring

Monitor precisely the filling operation to check whether the filling of each capsule is correct. The preparation of powder formulations and granules is the key element of operations in the environment of the pharmaceutical industry. Correct filling of capsules is vital to the quality of the dosage.

Assessing Uniformity

After the filling procedure, verify the capsules to ensure that they comply with the standard of uniformity/dosage. Check the body for any deviation, which can be underfilling or overfilling of capsules. In this case make the necessary corrections.

Extra Material Removal During Filling

Clean the capsules from any residual material using a suitable method, which can be vacuuming or brushing. This eliminates contamination and keeps the target unit free of any possible harm.

Ejection

At last, seal or put on the top cap of the capsule and eject the machine’s tray or plate. Ejectors are of great importance in this regard. Later, transit them to the respective stage of packing.

Considerations for the Effective Use Of Capsule Filling Machines

Capsule Filling Process
Capsule Filling Process

Machine Calibration and Adjustment

Before the launching of the capsule filling machine, appropriate calibration and adjustment is essential. According to the correct calibration, dosing will be precise, and you can experience uniform filling. Optimize the performance by carrying out frequent checking and calibrating of this machine.

Quality of Filling Material

The type of the filling material is one of the important factors in the result. Confirm that the filling material conforms with the regulatory requirements and that any contaminants are not present. The use of low-grade filling material can adversely affect the quality and safety.

Capsule Size and Compatibility

Choose the right size of the capsule according to the filling machine. Mismatched capsule sizes may lead to problems like jamming, incorrect filling, and capsule damage. Hence, the capsules have to be made by the specifications of the filling machine that you are using.

Sanitization and Hygiene

Be very careful and sterilize all protocols while working with the capsule filling machine. Maintain the cleanliness of all the components by constantly performing sanitation and preventing contamination and cross-contamination.

Safety Precautions

Safety should be the paramount consideration when operating a capsule-filling machine. Study the machine’s safety measures as well as the rules it works by. You can achieve this by using the safety kits comprising of glasses and gloves. Don’t wear loose clothes and stay away from moving parts.

Monitoring and Adjustments

Check the machine while it is off. Make adjustments when required for optimum performance. Analyze factors like speed of filling, accuracy of dosage, and capsule placement. Do proper tweaking as per requirement.

Documentation and Record-Keeping

Ensure correct recording and keep comprehensive documentation for all the capsule machine operations. This involves calibration records, batch records, maintenance logs, and all deviations from the standardized process. The necessary documentation is crucial for the fulfillment of traceability requirements, and control of quality and aids in compliance with regulations.

For all your capsule-filling machines, contact LOM now.

More resources:

Types of Capsule Fillers – Source: LOM

Manual Capsule Filling Machine – Source: LOM

Cleaning Capsule Filling Machine – Source: LOM

Capsule – Source: WIKIPEDIA

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