How to Use an Automatic Capsule-Filling Machine ?

Using a capsule-filling machine can streamline your production process, whether you’re working in pharmaceuticals or supplement manufacturing. These machines can handle a variety of capsule materials like powders, granules, and even liquids. 

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In this post, we’ll cover how to use an automatic capsule-filling machine and the steps involved.

Understand how to select the right capsule size for your filling machine and ensure optimal performance and accuracy.

What is a Capsule-Filling Machine?

What is a capsule-filling machine? A capsule-filling machine automates the process of filling empty capsules with powders, granules, or other substances. This allows for consistency, speed, and precision in production. 

These machines are invaluable for high-production environments. They eliminate the need for manual filling, which can be time-consuming and prone to errors.

Step-by-Step Guide: How to Use a Capsule-Filling Machine

Let’s break down how to use a capsule-filling machine step by step:

1. Prepare the Machine

Before starting, ensure the machine is clean and ready for use. Follow these steps:

• Confirm the machine is assembled correctly.
• Choose the right capsule size for your product.
• Check that trays, hoppers, and compartments are properly installed.
• Ensure the raw materials—powders, granules, or liquids—are loaded into the hopper.

Preparing the machine correctly is crucial for ensuring smooth operation throughout the entire process.

2. Load Empty Capsules

Load empty capsules into the machine. This process involves separating the capsule caps from the bodies and positioning the bodies for filling. Capsule-filling machines often include trays or compartments to handle the following:

• Sorting and separating the capsule caps from the bodies.
• Aligning the capsule bodies for filling.

This automatic process helps speed up production while ensuring capsules are correctly oriented for the next steps.

3. Set Parameters

Use the machine’s interface to set the necessary parameters. This step involves:

• Setting the fill volume for each capsule.
• Adjusting the speed of the filling process.
• Enabling or disabling the mixing function (if using multiple substances).

These parameters ensure that each capsule is filled consistently with the correct amount of product, whether it’s powder, granules, or liquids.

4. Start the Filling Process

Once everything is set, the machine can begin filling the capsules. Here’s how it works:

• The machine’s dosing system dispenses the material into the empty capsules.
• Tamping pins compress the material to ensure consistent filling and remove any air pockets.

Automatic machines fill large quantities of capsules quickly, which is ideal for high-volume production. For more complex formulations, machines can be equipped to mix multiple ingredients within a single capsule.

5. Reassemble the Capsules

After the capsule bodies are filled, the machine automatically reattaches the capsule caps to the bodies. This step seals the capsules securely and prevents leakage or contamination. The reassembly process is automated and ensures each capsule is perfectly aligned and sealed.

6. Inspect the Capsules

Quality control is essential. After the filling and sealing process, inspect the capsules for any defects:

• Check for underfilled or overfilled capsules.
• Identify any damaged or improperly sealed capsules.
• Remove any defective capsules.

Many machines come equipped with a capsule rejection system that automatically removes capsules that don’t meet quality standards.

7. Capsule Polishing

Once the capsules are filled and sealed, they may have some powder residue on their surfaces. Capsule polishers are often integrated into the machine to remove excess powder and ensure that each capsule is clean and ready for packaging.

Key Features of Capsule-Filling Machines

Here’s why capsule-filling machines like Canaan’s are so effective in high-production environments:

Speed

Automatic capsule-filling machines are incredibly fast, filling thousands of capsules per hour. This dramatically increases production efficiency compared to manual methods. Machines designed for large-scale production can process anywhere from 24,000 to 400,000 capsules per hour, making them ideal for pharmaceutical industries.

Accuracy

Each capsule is filled with a precise, pre-measured dose. This level of accuracy ensures uniformity across all capsules, which is especially important in pharmaceuticals where precise dosages are critical.

Hygiene

Because the entire process is automated, human contact with the capsules is minimized, reducing the risk of contamination. This makes capsule-filling machines perfect for environments that require strict hygiene standards, such as the pharmaceutical industry.

Minimal Downtime

Automatic machines are designed to run continuously with minimal downtime. They require little maintenance during operation, which allows for uninterrupted production over long periods.

How to Maximize Machine Efficiency

To get the best results from your capsule-filling machine, follow these tips:

• Regular Maintenance

Regular cleaning and maintenance are vital for ensuring the machine functions properly. Remove product buildup from the filling components and check the machine for any signs of wear or damage.

• Monitor Capsule Quality

Frequently inspect the capsules during production. Look for capsules that are improperly filled, damaged, or incorrectly sealed, and remove them to maintain product quality.

• Choose the Right Machine for Your Needs

Select a machine that matches your production scale. Smaller machines are ideal for limited production runs, while larger machines can handle thousands of capsules per hour. Consider factors like production volume, capsule size, and the type of materials being filled when choosing a machine.

Types of Materials Used in Capsule Filling

Capsule-filling machines are versatile and can handle different types of materials:

• Powders: One of the most common materials for capsule filling. Machines can fill powders smoothly and consistently without clogging.
• Granules: Granules allow for controlled release in certain types of capsules. Machines handle these with the same precision as powders.
• Liquids: Some machines can fill capsules with liquids. Special equipment is used to prevent spillage or leakage during the process.
• Combinations: Machines can also fill capsules with a combination of materials, such as powders and granules, offering flexibility in product formulation.

Validation and Compliance for Capsule-Filling Machines

Capsule-filling machines must meet regulatory standards to ensure safety and effectiveness. Validation documents are typically provided with the machines to confirm compliance:

Factory Acceptance Testing (FAT)

Before shipping, FAT verifies that the equipment meets the design and operational requirements. The documentation includes:

• FAT protocols
• Test results
• Necessary maintenance or modifications

Site Acceptance Testing (SAT)

After installation, SAT ensures that the machine operates correctly in its intended environment. Documentation covers:

• Installation checks
• Test results to confirm the machine meets specifications

Installation Qualification (IQ)

This confirms that the machine is installed properly, including utilities and safety connections, ensuring readiness for operational testing.

Operational Qualification (OQ)

OQ ensures that the machine operates correctly under actual production conditions, confirming it meets performance standards.

Final Thoughts

Using a capsule-filling machine significantly enhances production efficiency in industries like pharmaceuticals. By automating the entire capsule-filling process, these machines ensure precision, consistency, and high-quality output. 

Why Choose Canaan for Your Capsule-Filling Machines?

Canaan’s automatic capsule-filling machines come with certifications, ensuring compliance with international safety, health, and quality standards. They confirm that our machines meet rigorous safety protocols and deliver reliable, high-quality performance. 

With Canaan’s machines, you can confidently manage large-scale production, knowing that every step—from capsule filling to sealing—is handled with precision and minimal risk of contamination.

For more information, visit our website or get in touch with us!