Capsule filling machines are widely used in manufacturing industries. They are used to fill empty capsules with materials like powders or granules. They ensure consistent and precise dosages. This is vital for patient safety and treatment efficacy.
Capsule fillers come in three types. Each of them has unique pros and cons. If you require high-volume production, fully automatic capsule fillers are ideal for your business. This post helps you get more understanding of this machine and then increase your product efficiency.
What is an Automatic Capsule Filler?
Automatic capsule filling machines are used to fill the empty capsules totally by itself. They can complete the whole process from material filling to capsule ejection with minimal human intervention. Due to their high efficiency and production, these machines are a good choice for large-scale pharmaceutical manufacturing.
Automatic capsule filling machines feature high efficiency, capable of filling thousands of capsules per hour. This efficiency is a significant advantage over manual and semi-automatic machines. The automated processes eliminate the need for manual handling at multiple stages. So the production time is greatly reduced and output is majorly increased.
In addition, these machines can handle different types and sizes of capsules. This flexibility allows them to handle a wide range of formulations and batch sizes.
Working Principle of Automatic Capsule Fillers
Their main structures include a workbench, polishing barrel, sorting device, inlet and outlet, dust collection system, etc. All of them meet the requirements of GMP clean workshops. They work together to complete the filling task. The working process is as follows.
First, the machine loads empty capsules from a hopper into designated stations. In this place, they are oriented and positioned for filling. The fill material, like powder, is then accurately measured and dispensed into each capsule. After filling, the capsules are sealed to prevent any spillage or contamination. The completed capsules are then ejected from the machine, ready for further processing or packaging.
You can check the video to see clearly.
Automatic capsule filling machines provide accurate and uniform results throughout the operation. This includes precise dosing systems that measure the fill material accurately. Automated controls are equipped to adjust settings to accommodate different types of capsules and fill materials. By integrating these technologies, automatic machines achieve high production speeds and maintain stringent quality control.
Eight Applications of Automatic Capsule Filling Machines
There are many uses for automatic capsule fillers. They can be applied to fill different materials, such as powders, granules, liquids, etc.
Powder-Filled Capsules
Automatic capsule filling machines are commonly used for filling powder into capsules. The powders can include active pharmaceutical ingredients (APIs), excipients, or both. These machines can precisely control the amount of powder, ensuring uniform and accurate doses. Automatic capsule fillers also have a sealed area for operation. That reduces the risk of powder splashing and accidental injuries.
Granule-Filled Capsules
Granules are small, round particles made from powders through granulation. Because raw materials with high density or other properties may not be suitable for direct capsule filling. Granules are usually used in controlled-release formulas or to improve a drug’s solubility and effectiveness.
Besides, some companies make granules from herbs. At first, they boil herbs into a liquid, then concentrate it and mix it with excipients to form dry granules. These granules are then put into capsules. This method helps preserve the active ingredients of the herbs. It also makes them easier to store and use. Herbal granule capsules are often used as dietary supplements or medicines.
Pellet-Filled Capsules
Pellet-filled capsules are a type of medication where small, spherical pellets are put inside a capsule. These pellets are uniform in size and shape. And they are smaller than granules. Each pellet contains active ingredients, and coatings control how the drug is released. There are many different types of pellets. They include immediate release pellets, extended release pellets and controlled release pellets.
It provides extra protection by putting pellets into capsules. It prevents the pellets from being damaged during storage and transport. The capsule also ensures that each dose is consistent and prevents the pellets from separating. This helps keep the drug stable. It also becomes easier for patients to follow their treatment.
Liquid-Filled Capsules
Liquid-filled capsules contain liquid substances such as oils, suspensions, or solutions. These are often used for formulations that require rapid absorption. Some some contain sensitive ingredients that need protection from degradation.
Automatic machines are equipped with liquid dosing systems, such as piston pumps or peristaltic pumps. They can accurately measure and dispense the liquid into the capsules. They provide high precision and consistency, reducing the risk of dosage errors and leaks. These machines also allow for high-speed production, making it suitable for large-scale operations.
Tablet Fills
Tablet-filled capsules are a type of medication where tablets are placed inside a capsule shell. This allows different tablets to be combined into one capsule. So it is much easier for patients to take multiple medications at once. This dosage form simplifies the medication process, reduces the patient's burden, and improves adherence to the treatment. Tablet-filled capsules are especially useful in treating conditions like high blood pressure and diabetes.
Additionally, this approach combines the benefits of both tablets and capsules. The capsule shell hides any unpleasant taste of the tablets. It also provides extra protection and swallowing convenience.
Combination fills
Combination fills involve filling capsules with more than one type of material, such as a mixture of pellets and powders. This can be used to achieve specific therapeutic effects or release profiles. For handling these capsules, you must choose the equipment that is able to deal with different materials. If you can’t find the machine you need on the market, you can contact a manufacturer to customize it.
The categories mentioned above are based on the different types of filling materials. Next, I will introduce two applications of automatic capsule fillers for different capsule shells. The shells are always made of gelatin or plant fibers. The former is used more widely, and the latter is mainly suitable for vegetarians.
Hard Capsules
Hard capsules are the most commonly used capsule type in pharmaceutical manufacturing. They consist of two parts: a body and a cap. They can be handled by automatic fillers for aligning, filling, and sealing. The machines use mechanisms such as rotary filling systems or volumetric dosing units to handle these capsules accurately. Automatic capsule fillers can be applied to different sizes and types of hard gelatin capsules.
Soft Capsules
Soft capsules are also known as softgels. They are used for liquid or semi-solid formulations. Sofgels are sealed with a soft, pliable gel in one piece. Due to their unique properties, they require automatic machines equipped with liquid dosing systems. So it can ensure high precision and prevent leakage, maintaining the integrity of the product.
The End
Automatic capsule filling machines provide efficient, accurate, and high-speed solutions for a wide variety of formulations. They greatly enhance production efficiency, reduce labor costs, and minimize human error. If you are looking for high-quality automatic capsule fillers, come to Huada Pharma.
We provide a wide range of capsule filling machines to meet your needs. You just tell us your demands, and we can choose the most suitable one for you. If you have any questions, feel free to contact us.