Capsule filling machines are crucial for manufacturing industries—especially for pharmaceutical businesses. However, selecting the right machine for a specific product can be challenging. Many users find themselves confused about how to effectively use the capsule filling machine.
That’s why we’re providing complete information on how to use capsule filling machines effectively. Continue reading to gain a better understanding:
How To Use A Semi-Automatic Capsule Filler
Semi-Automatic Capsule Fillers: A semi-automatic capsule filling machine requires partial manual operation combined with mechanical assistance for higher efficiency, ideal for medium to large batch sizes.
Let us have a look at two types semi-automatic capsule machines by SEDPHARMA!
SED-BJ-I-A capsule filler uses electropneumatic joint control, and it is equipped with touch switch, programming control, frequency conversion and speed regulating device. It can respectively complete various steps including putting the capsule in place, separating, filling, locking and so on. Instead of manual filling, this machine can reduce the labor intensity, and improve production efficiency. It has accurate filling dose and meets the requirements of medicine hygiene.
This machine is composed of the mechanism of capsule turning and separating, the filling mechanism, the locking mechanism, the frequency converter and speed regulating mechanism, the pneumatic control and electrical control system, the protection device and other parts as well as the accessories of the vacuum pump and the air pump.
The domestic or imported capsules all can be applied, and the qualified rate of the finished product can reach more than 98%.
Commissioning and Operation of SED-BJ-I-A Capsule Filler
The following shows the main interface:
(1)The vacuum pump starts and stops by the computer control panel (ON/OFF), when the ON is pressed, the vacuum pump starts to run, while the solenoid valve operates; When the OFF is pressed, the vacuum pump stops running (the vacuum pipe system is equipped with a filter to prevent empty capsule debris from entering the vacuum pump, and the filter is equipped with a vacuum gauge to display the system pressure)
(2)Air pump start and stop: (the principle is the same as the vacuum pump system) Press the ON to start, and the OFF to stop.
(3)The start and stop of capsule-feeding: the capsule-feeding mechanism takes a single motor as the power source, is controlled by the frequency converter, and adjusts the speed through the knob. When the ON is pressed, the mechanism is started, and the OFF key is pressed to stop the mechanism. When the capsule-feeding starts and runs to the set data of the counter (setting value of the count when leaving the factory is 60 times), the capsule-feeding will automatically stop.
(4)The filling mechanism can run when the quadratic frequency conversion and continuously viable (CV) motor respectively drive the hopper, the turntable, the cylinder, solenoid valve and counter to coordinately operate. The speed of the hopper and the turntable are respectively operated by the setting data of the frequency converter. When ON is pressed, the solenoid valve is activated to open the air duct, and offer air to the cylinder, then the cylinder pushes the medicine into the turntable. When the cylinder is in operation, the delay timer is timed at the same time (factory debugging sets the delay timer as 2 seconds). After the hopper reaches the position, the time delay device will be finished, which means that the command turntable and the hopper motors start to run. In the meanwhile, the turntable will be counted. When the turntable moves to the setting position (factory debugging sets 30 times for one circle), the turntable and the hopper motors will stop running at the same time, and the solenoid valve is also returned to make the cylinder operate and to pull the hopper back.
Loading adjustment mode of semi-automatic capsule filling machine:
1) Press (Mode) button -- Display (00);
2) Press the (Set) button -- Display (88) and then press (▼) -- Display (8);
3) Press (Set) button -- then press (mode) -- then press (▲) -- display (113);
4) Press the (Set) button -- Display (known frequency) -- (▲▼) -- (required frequency) -- (set).
5) The protective device prevents hands or hard objects from entering the capsule-feeding mechanism in operation. The structure is a protective door blocking the working face of the capsule-feeding head, and there is a micro and limit switch interlocked with the capsule-feeding control line under the door shaft (inside of the machine body). When the door is opened, the capsule-feeding motor stops immediately and the indicator on the panel lights up.
Equipment Operation
(1)Before operation, the operator is required to be familiar with the contents of this manual, understand the working performance of each component of the machine, and the role of each button on the control panel.
(2)Check whether the parts of the machine are in good condition, and fuel the lubricating parts according to the regulations.
(3)Turn on the power and turn off the air switch on the electric control box. When the red button on the control panel indicator light, press the vacuum start button ON to check whether the direction of rotation of the vacuum pump motor is consistent with the direction indicated by the arrow. Press the air pump button ON to check whether the rotation direction of the air pump motor is consistent with the direction indicated by the arrow.
(4)When starting the vacuum pump and the air pump, the rotation direction must be consistent with the direction indicated by the arrow, adjust the frequency lower, and then start capsule-feeding motor. Press the ON and gradually increase the speed of the capsule-feeding to the maximum. Determine the running speed based on the quality of the empty capsules you purchased.
(5)The better the capsule quality, the higher the capsule feeding speed, and vice versa. Fasten the lower mold on the turntable, pour the drug into the hopper, and press the ON to fill the capsule.
(6)Harness the upper mold to the lower mold that has been filled with medicine, and move them simultaneously toward the locking station so that the die thimble is inserted exactly into the die hole. Let the locking cover turn down, and gently tap the pedal valve to lock the capsules and make them flow into the collector box.
(7)Turn off the power supply. The power should be turned off when the machine is not working.
SED-BJ-III-A Semi-Automatic Capsule Filling Machine can complete capsule sewing, separating, filling, locking, etc.
The machine adopts PLC, touch screen, stepless transduction speed-shift, and electronic automatic counter. The dosage is accurate, and the operation is convenient. The overall machine is made of 304 stainless steel, in line with GMP requirements.
Commissioning and Operation of SED-BJ-III-A Capsule Filler
The following shows the main interface:
1）The vacuum pump starts and stops by pressing Vacuum Pump ON, while the solenoid valve operates at the same time; When pressing Vacuum Pump OFF, the vacuum pump stops running (the vacuum pipe system is equipped with a filter to prevent empty capsule debris from entering the vacuum pump, and the filter is equipped with a vacuum gauge to display the system pressure)
2）The start and stop of capsule-feeding: When the ON is pressed, the mechanism will be started, and the OFF is pressed to stop the mechanism. The capsule-feeding mechanism takes a single motor as the power source, which is controlled by the frequency converter, and the rotation speed can be adjusted by setting the speed value of capsule feeding. When the capsule-feeding starts and runs to the setting data of the counter (the setting value of the counter is 60 times when leaving the factory), the capsule-feeding will automatically stop.
3）The filling mechanism can run when the quadratic frequency conversion and continuously viable (CV) motor respectively drive the hopper, the turntable, the cylinder, solenoid valve and counter to coordinately operate. The hopper and the turntable are respectively operated by the setting data of the frequency converter. When Filling ON is pressed, the solenoid valve is activated to open the air duct, and offer air to the cylinder, then the cylinder pushes the medicine into the turntable. When the cylinder is in operation, the delay timer is timing at the same time (factory debugging sets the delay timer as 2 seconds). After the hopper reaches the position, the time delay device will be finished, which means that the command turntable and the hopper motors start to run. In the meanwhile, the turntable will be counted. When the turntable moves to the setting position (factory debugging sets 30 times for one circle), the turntable and the hopper motors will stop running at the same time, and the solenoid valve is also returned to make the cylinder operate and to pull the hopper back.
4）Capsule-discharging mechanism: after pressing capsule-discharging ON, a whole set of discharging action will be ready, and pressing Capsule-discharging Inching, the discharging action will be started; stop pressing, the operating also will be stopped.
5）Protective device that is used to prevent hands or hard matters from entering the capsule-feeding mechanism. The structure of it is that there is a door blocking the capsule-feeding station and the door’s shaft is equipped with a micro limit switch interlocked with the capsule-feeding control circuit, so when the door opens, the capsule-feeding motor will be stop immediately.
Click Parameter Setting to enter the following interface
By clicking on each motor, you can individually control the start of the corresponding motor and at the same time modify the parameters according to production requirements.
Click capsule-feeding servo to enter the following interface
This interface adjusts the position and speed of the capsule-feeding servo. By starting and stopping the capsule feeding, it can test the optimum value, and then clicking Return to continue production.
Equipment Operation
(1)Before operation, the operator is required to be familiar with the contents of this manual, understand the working performance of each component of the machine, and the role of each button on the control panel.
(2)Check whether the parts of the machine are in good condition, and fuel the lubricating parts according to the regulations.
(3)Turn on the power and turn off the air switch on the electric control box. Press the air pump button ON to check whether the rotation direction of the pump motor is consistent with the direction indicated by the arrow.
(4)When starting the vacuum pump and the air pump, the rotation direction must be consistent with the direction indicated by the arrow, adjust the frequency lower, and then start capsule-feeding motor. Press the ON and gradually increase the speed of the capsule-feeding to the maximum. Determine the running speed based on the quality of the empty capsules you purchased.
(5)The better the capsule quality, the higher the capsule feeding speed, and vice versa. Fasten the lower mold on the turntable, pour the drug into the hopper, and press the ON to fill the capsule.
(6)Harness the upper mold to the lower mold that has been filled with medicine, and move them simultaneously toward the locking station so that the die thimble is inserted exactly into the die hole. Let the locking cover turn down, and gently tap the pedal valve to lock the capsules and make them flow into the collector box.
(7)Turn off the power supply. The power should be turned off when the machine is not working.
How To Use A Full-Automatic Capsule Filler
SED-7500J-C Automatic Capsule Filling Machine is commonly used in the pharmaceutical, nutraceutical industries to fill empty hard gelatin capsule of various sizes with powders and pellets (optional). The capsule filler automatically orientates, opens the empty hard gelatin capsule, properly fills the capsule with powder, and automatically closes the capsules.
Replacement Method of Filling Molds
To change the filling molds, users must replace the upper and lower molds, capsule feeding plate, horizontal fork, vertical fork, standard block, filling rod, and dosage tray.
Filling Mold Replacement Method
Loosen the fastening screws of the upper cover plate of the rotary table to remove the upper cover plate and then loosen the fastening screws of the upper and lower molds to remove the upper and lower modules. When loading, put the lower mold into the T-axis of the two pins, after positioning, and then tighten it, and then load the upper mold. Mold adjusting rod should be installed at the eighth station, and at the eight stations, each pair of molds should be inserted into the left and right outside of the two mold holes in the alignment. Then tighten the screws, to ensure that the debugging lever in the upper and lower mold hole rotates flexibly.
Components Feeding Replacement
1. Disassembly
a. Loosen the two fastening screws of the capsule hopper and remove the screws and the hopper;
b. Carry the main motor shaft with the handle so that the capsule feeding plate runs to the highest position;
c. Unscrew the four fixing screws on the bladder delivery plate and remove the bladder delivery plate;
d. Unscrew the two fastening screws on the correction block and remove the correction block;
e. Unscrew the screw on the horizontal fork and remove the horizontal fork;
2. Replacement and installation:
a. Align the two positioning holes of the standard block with the pin on the magazine to locate and then tighten the upper screw;
b. Align the two long grooves on the horizontal fork with the pin on the horizontal slide plate, and place them on the horizontal slide plate, and then adjust them. When they push the corresponding capsules to the optimized position, tighten the screw (It generally refers to that the horizontal fork pushes capsule body to the outer end of the standard block);
c. Align the two positioning holes of capsule-feeding plate and the back plate with the pin on the straight slide plate, after positioning, and then tighten the upper screws;
d. Install the fixed plate, put in two capsule funnels and then tighten the screws. (When installing the funnels, pay attention to the uniformity of the gap between the rectangular groove and the periphery of the capsule delivery plate);
e. After replacing the parts of the capsule feeding plate, put some empty capsules in the funnel, start the vacuum pump, open the release capsule mechanism, and rotate the machine with the handle to make sure that the capsules are correctly broadcast and separated.
Note: There are 2 columns between the bottom of the feeding mechanism and the working table, which are the big column and the small column. When replacing different types of molds, users need to add different size shims between the big column and the small column and the working table respectively. Refer to the table below:
| Name (of a thing) | Large Column |
| 3#,4# | Without shims |
| 2# | (1.5mm) Spacer 1pc, (3mm) Spacer 1pc |
| 0#, 1# | (1.5mm) Spacer 1pc, (3mm) Spacer 1pc |
| name (of a thing) | Small Column |
| 3#,4# | Without shims |
| 2# | (1.5mm) Spacer 1pc, (3mm) Spacer 1pc |
| 0#, 1# | (1.5mm) Spacer 1pc, (3mm) Spacer 1pc |
Replacement of Dosage Tray and Filling Rod
a. Loosen the fastening screws to raise the powder hopper by spring force;
b. Use a vacuum cleaner to suck up the remaining powder in the medicine pool ring;
c. Turn the main motor with the handle so that the punch rod seat disk is in the highest position;
d. Loosen and take down cap nut and turn the knob clockwise (see Figure 21) to raise the filling gripper and drop it down;
e. Remove the screw of small pressure plate with a long hole under the clamp and remove the filling rod. Replace the filling rod and press on the small pressure plate to tighten the screws for installation;
f. First loosen the screws on the rail upward to draw out the rail (see Figure 16), unscrew the two fastening screws at both ends of the powder ring cover, use the handle to rotate the main motor accordingly, and loosen the four fixing screws. The powder ring and the cover are slowly lifted away from the dosage plate together with the side to take out, do not have to unload the punching rod seat plate;
g. Remove the three screws fastening the dose tray with a special wrench and then remove the dose tray;
h. After removing the powder in the bracket, install the dosage tray with required specification, and do not tighten the three fastening screws after installing them;
i. Use the handle to rotate the main motor accordingly, so that the punch rod seat plate is lowered to the lowest position. The two dosage plate correction rods are inserted into the different holes of punch rod seat plate. At this time, to carefully and appropriately rotate the dosage plates, so that the correction rod is inserted smoothly into the hole. Then carefully tighten the three screws in turn, after tightening, if the correction rod cannot be smoothly inserted into the dose tray, it must be readjusted until the smooth insertion;
j. The powder ring and cover plate need to be installed from the side. Use the handle to rotate the machine, tighten the four fixed powder ring screws, if the replaced dosage plate is thicker than the original one, users need to first adjust the powder dispenser upward;
k. Tighten the cover plate fixing screws, and then carefully adjust the height of the powder dispenser, keeping the gap between the powder dispenser and the dosage disk 0.05 ~ 0.1mm, and then tighten the lock nut;
l. Attach the filling rod and gripper and platen in their original positions and tighten the cap nut;
Adjustment after Mold Replacement
When replacing the mold specifications each time, the machine must be properly adjusted. Rotate the main motor with handle, so that the machine running 1 ~ 2 cycles, if you feel abnormal resistance, immediately stop running, find out the faults and eliminate them until the normal state.
Adjustment of the Whole Machine
Adjustment of the Capsule Funnel Outlet: (see Figure 12)
The capsule baffle installed on the funnel can control the height of the capsule outlet, if loosen the pulling baffle of baffle fixed knob nut, you can change its height. Experience shows that the height of the exit for the capsule exit height of 1/2 is better.
Adjustment of the Buckling Mechanism: (see Figures 13 and 14)
The opening and closing time of the buckled capsule reed is to ensure that one capsule is discharged from the capsule delivery plate for each action. Adjustment method is: loosen the tightening screw of the limit block, move the limit block, so that each action to meet the above requirements, and block the waiting capsule at the position shown in the Figure.
Adjustment of Vacuum Separator: (see Figure 15)
The vacuum separator runs up and down once for every station of the machine. The station of the vacuum separator has been adjusted when the product is shipped from the factory, so it is generally not necessary to adjust it. If adjusting, there are two methods can used, one is to adjust the two vacuum separators at the same time, the other is to adjust the two vacuum separators respectively. The former one is that to rotate the main motor shaft with the handle, so that the vacuum separator rises to the highest position, loosen the both ends of locking nut (left and right threads) under the panel of the adjusting rod. Rotate the adjusting rod to adjust the height of the vacuum separator, (which separates the upper panel and lower mold, keeping the gap for 0 to 0.03mm) then tighten the locking nut and double-check a few times until it is suitable. If the gap between the two upper planes and the lower module is not consistent when there are two vacuum separators at the highest point, they need to be adjusted separately. The method is: use the handle to rotate the main motor shaft, so that the vacuum separator rises to the highest position, loosen the machine under the table panel to adjust a group of cross-bar screws, and then the upper and lower.
Move the suction capsule valve tappet, adjust the height of the vacuum separator, and then tighten the screws. Finally, put the empty capsule in the capsule delivery device, start the vacuum pump and turn the machine with the handle to make sure the capsule separation is normal.
When replacing the module or found in the same module always appear capsule cannot be separated or buckle bad phenomenon, users must adjust them in the concentricity of the module hole, and adjustment method with 5.1.1 in the description.
Adjustment of the Gap between the Dosage Disk and the Sealing Ring: (see Figure. 16 and Figure. 17)
Dosage disk and sealing ring gap should be between 0.03 ~ 0.08mm. The gap can be adjusted larger if the particle is big, as small gap will increase the resistance between the dosage disk and sealing ring. If the machine is found to leak too much powder in operation or resistance is too large, the gap should be adjusted. Adjust the gap is: loose and remove the five screws on the plate, loosen the set screw and set nut, in turn, evenly and carefully turn the five adjusting bolts to adjust the height of the sealing ring up and down, with a ruler to detect the gap, test three to five points, and the gap value of the points should be the same, and to ensure that the five adjusting sets and sealing ring contact. After the test is completed, first tighten the set nut and test the gap again, after confirming that there is no error, the plate should be installed on the rail with screws to fix it.
Gap Adjustment of Powder Separator: (see Figure 18)
After each replacement of the dosage plate, the gap should be adjusted with between 0.05 ~ 0.1mm for the best. The adjustment method is to loosen the lock nut, turn the adjusting screw, make the powder dispenser rise or fall, after checking the gap with a ruler, tighten and screw the nut.
Adjustment of Filling Rod Height: (see Figures 19, 20 and 21)
Adjusting the height of the filling rod can change the density of the column and the amount of drug. When the filling rod height is adjusted appropriately, you can get a precise amount of drug. The depth of the filling rod into the dosage tray can refer to the dimensions in the table, and it should not be too deep (see Figure 4 for status). The lower end of the pointer is aligned with the "0" line on the scale on the filling rod holder, which means that when the rod holder is at the lowest position, the lower plane of the filling rod and the lower plane of the dosage tray are in the same horizontal plane. Adjustment method: first loosen the lock nut on the adjusting screw, rotate counterclockwise to connect the adjusting screw corrugated handwheel to make the filling rod rise, and then rotate the handwheel clockwise to make it fall to the required height after the lock nut is tightened. Above steps can only be adjusted from high to low and then tightened. (Note when the thickness of the dosage tray is 18mm)
| Station | 1 | 2 | 3 | 4 | 5 |
| Depth into Dosage Tray | 9 | 5 | 3 | 2 | 0.5 |
Adjustment of Module Cleaning Devices: (see Figure 30)
The tenth station is equipped with a module cleaning device, which requires clean air at a pressure of 0.3 MPa. There is an air regulating valve and a pressure gauge under the machine frame panel to adjust the air pressure to 0.3Mpa for cleaning the module before running the machine.
The tenth position is equipped with a cleanup suction head on the table surface, which can clean out the powder of the module holes to ensure that the next capsule feeding work is normal operating. The adjustment of its washing head is: loosen the screws, adjust the gap between the bottom of the suction head bottom and the upper plane of the upper module to 0.5 ~ 1mm, and then tighten the locking screws.
Adjustment of Torque Overload Safeties: (see Figure 31)
Torque overload device is installed reducer output device in the main motor, which plays a role in protection when the machine is overload. The device should not slip when the load is normal, but due to prolonged use, the interface will occur. When it slips in the normal operation, you can tighten the nut to ensure the normal operation of the machine and protective function of the device.
Adjustment of the Drive Chain: (see Figure 32)
When the chain is too loose, the tensioner wheel needs to be adjusted. The arbor of the tensioner wheel is eccentric, so loosen the lock nut first when adjusting. Then turn the arbor of tensioner wheel to make the chain get proper tension, and then tighten the nut again. Be careful not to disengage the chain from any sprocket when adjusting, let alone open the chain, so as not to disturb the movement law of the whole mechanism.
Adjustment of Vacuum Degree: (see Figure 33)
Water cycle vacuum pump uses clean water. Vacuum degree can be adjusted with the vacuum degree adjustment valve, (such as the configuration of oil-free vacuum pump, no inlet and outlet pipes, while the vacuum gas pipeline unchanged). Vacuum degree can be read out on the vacuum table, in which will keep -0.02 ~ -0.06Mpa when sucking capsule to ensure that the capsule can be separated and does not damage them as well. When the vacuum degree is too high, you can open the vacuum adjustment valve appropriately; when the vacuum is too low, turn down or close the adjustment valve.
Contact Person: Ms. Wei
Tel: 86-15372434551
Fax: 86-571-88615836
