Capsules and softgels are popular in the supplement industries. They are always made by capsule filling machines. These machines come in various types, including manual, semi-automatic, and fully automatic models. Each of them are suited to different production scales and requirements.
Safety is a critical concern in capsule filling operations. Because it directly impacts the quality of the final product, and the safety of workers. If you don’t operate the machine properly, it can lead to contamination, incorrect dosages, or even injury to operators. Therefore, it is a must to have a further understanding about how to safely operate capsule fillers. Here are 8 tips to help you get a safer operation.
Personnel training
No matter which type of capsule filler is being used, operators need to have a deep understanding for precise handling. So personnel training is a must. It always includes the following program.
- Understand the machine. It helps operators understand the parts and working principles of the machine. This allows them to use the machine more easily and correctly.
- Safety protocols. It teaches how to wear protective gear and follow hygiene steps.
- Handling materials correctly. If not, problems may occur, especially contamination. So, it is very important to understand how to handle capsules and filling materials safely before starting work.
- Regular maintenance and troubleshooting. This part of the training shows how to clean, oil, and adjust the machine regularly. It also teaches how to spot and fix common problems with the machine.
- Following regulations. Operators should know some key industry rules, such as FDA, and GMP.
Proper training helps operators learn how to use the machine safely. This keeps workers safe while also making sure the production process stays smooth. It can ensure the products are always made at a high quality. Trained workers can also spot small problems before they grow bigger. It saves time and money by avoiding repairs or product recalls.
Ensure the emergency button works and know the shutdown process
The emergency button is a key safety part of the machine. It lets workers stop the machine right away if something dangerous happens. Before using the machine, workers should make sure the button works well. This means you need to check how quickly it reacts when pressed. You should also check if it is easy to reach the button during an emergency.
Also, you need to know what to do in emergencies. You should practice handling different emergency situations regularly. This helps you make quick and correct choices when things go wrong.
Keep the work environment clean and safe
A clean work area helps prevent accidents. If your workspace is messy, you might trip, slip, or make mistakes with your equipment. It can lead to safety risks. Also, if tools or loose materials are lying around, they might get in your way or get caught in the machine. It would problems or injuries.
In addition, this affects the machine’s work performance. If dust and dirt get into the machine's important parts, they can make the machine wear out or break. Even worse, these contaminants can get into the capsules and make the final product less safe and lower in quality.
Wear PPE
You would contact different materials when using the capsule filler. Some of them can be harmful to health. In addition, the machine has moving parts and mechanical actions that can be dangerous. PPE (Personal Protective Equipment) is like a shield that keeps you safe from both the materials and the machine's moving parts.
- Masks and gloves can avoid touching or breathing in harmful stuff. This helps prevent allergies and rashes. Gloves also help protect hands from being pinched or cut during machine operation.
- Safety glasses and work clothing keep operators safe from flying particles. They guard the eyes and skin from harm.
- PPE stops operators from bringing germs from outside. This helps keep the products clean and makes sure the products are made according to hygiene rules.
Check the machine before operation
Before the machine gets started, a careful check is needed to make sure it's safe and works well. The most important thing is to check the installation of parts. Check if all moving parts, like the filling head and conveyor belt, are properly installed and securely connected. Any loose or incorrect installation can cause machine failure or even injury. Accurate calibration is also important. This ensures smooth operation and reduces the risk of damage.
Moreover, electrical safety is crucial when operating any industrial equipment. You’d better inspect all electrical connections, like power plugs if they are intact or securely connected. Loose or damaged connections may lead to electrical failures, fire, or electric shock.
Monitor the operation
Operators start the machine at a low speed and check if the initial steps, such as capsule separation and filling, are working properly. You need to pay close attention to any unusual noise, vibrations, or issues. If everything runs smoothly at low speed, you can gradually increase the speed. But you should continue to monitor each step of the filling process. Once all stages are confirmed to be normal, the machine can reach full speed. And you should keep monitoring its performance to ensure smooth production.
Clean the machine after use
It’s better to clean the capsule filling machine thoroughly after each use, especially when changing formulas or products. This step is crucial to prevent cross-contamination. If leftover powder or other materials are not properly cleaned, they might contaminate the next batch. It will make the final product fail to meet quality standards and possibly posing health risks to consumers. Cleaning also keeps the machine working at its best.
Powder, granules, or other filling substances can build up on many places like conveyor belts and filling molds. This may cause the machine to run less smoothly or even break down. Regular cleaning helps reduce wear and tear, and extends the machine's lifespan.
Regular maintenance
The capsule filling machine is a precise piece of equipment with many moving parts. If these parts do not receive regular maintenance, they may fail due to wear, dust buildup, or lack of lubrication. Regular maintenance helps find and fix potential problems, preventing failures and keeping operators safe.
Key parts, like bearings and slides, need maintenance once a week. You can use the right lubricant to ensure smooth operation and reduce wear. Also, you should check seals and gaskets monthly. You can replace these parts if needed to prevent leaks. For maintenance every three months, you can perform a deep cleaning and disinfection, especially in hard-to-reach areas.
The End
As China’s leading pharma equipment supplier, Huada Pharma offers a wide range of machines, such as capsule filling machines, tablet press, etc. we can provide the full service from design, through to the delivery of complete turn-key pharma process and packaging solutions. You just tell us your requirement and we can quickly select the machine to meet your needs. We also have a professional technical team to help you ensure a safe operation.